Steel pipe sheath extrusion forming and production equipment and method for umbilical

Abstract

The present application relates to the field of cable, especially to a steel pipe sheath extrusion forming and production equipment and method for umbilical cable, the production equipment comprises a pay-off device, a straightening device, a detection device, an extrusion forming device and a take-up device, the straightening device is used for straightening treatment of the steel pipe, the detection device is used for roundness detection of the steel pipe, and the extrusion forming device is used for coating a sheath layer on the outer surface of the steel pipe, the steel pipe is preliminarily guided and straightened through a guide straightening assembly, the steel pipe is precisely straightened through a roller straightening assembly, residual local deformation of the steel pipe is eliminated, the straightening effect is further optimized, and small-scale snaking caused by incomplete or excessive straightening of the guide wheel is avoided.

Description

Technical Field

[0001] This invention relates to the field of cables, and more particularly to an extrusion molding and production equipment and method for steel pipe sheaths for umbilical cables. Background Technology

[0002] In recent years, driven by the wave of offshore energy development, the application of umbilical cables has become increasingly widespread. In the operation of deep-sea oil and gas platforms and ROVs and other underwater equipment, umbilical cables are core components, connecting the upper floating platform to the subsea production system. They provide the subsea production system with essential electrical and hydraulic power, monitoring and control data signal transmission, and chemical injection, among other functions, earning them the title of the "nerves and lifeline" of the subsea production system. The manufacturing process of umbilical cables is highly technologically advanced, and currently only a few companies worldwide are capable of completing their processing and manufacturing.

[0003] In umbilical cable structures, steel pipe units (usually stainless steel pipes) play a crucial role as hydraulic / chemical agent delivery channels and structural supports. Depending on the working conditions, non-metallic or stainless steel pipes can be used as the delivery conduits for the working fluids. The manufacturing and sheathing extrusion process of steel pipe units typically involves a series of steps, including laying out, straightening, preheating, extrusion coating, cooling, traction, and winding. Currently, the main production process for steel pipe sheathing extrusion molding is as follows: the coiled steel pipe is fed into a straightening device via multiple sets of guide wheels for initial straightening, then heated by a preheating device, and finally coated with a layer of polymer sheathing material through an extruder head. After cooling and shaping in a cooling water tank, it is pulled to the winding equipment by a traction device.

[0004] During the initial processing (rolling, welding), transportation, storage, and laying out of the steel pipe, bending deformation is inevitable, resulting in non-compliance with straightness standards. Existing straightening devices are mainly conventional structures such as roller type, pulley type, and pressure roller type, which have two main drawbacks: First, the steel pipe has a hollow internal structure, and when using only one type of straightening mechanism for production, the straightening and extrusion process can easily cause surface depressions in the steel pipe, affecting the extrusion process quality of the steel pipe sheath; second, existing guide wheel type and roller type longitudinal and transverse step-by-step straightening devices still have local bending residues after straightening, causing a serpentine shape that affects the concentricity and coating uniformity of subsequent sheath extrusion. Summary of the Invention

[0005] This invention aims to at least solve one of the technical problems existing in related technologies. To this end, this invention proposes an extrusion molding and production equipment for steel pipe sheaths used in umbilical cables, to address the problem of poor straightening effect in existing straightening devices.

[0006] The extrusion molding and production equipment for steel pipe sheaths for umbilical cables according to an embodiment of the present invention includes: arranged sequentially along the moving direction of the steel pipe, comprising: Paying-out device; A straightening device used to straighten steel pipes; The testing device is used to inspect the roundness of steel pipes; Extrusion molding equipment for coating a sheath layer onto the outer surface of a steel pipe; and Retractor; The straightening device includes a guide straightening component and a roller straightening component arranged sequentially along the moving direction of the steel pipe. The guide straightening component is used to initially guide and straighten the steel pipe, and the roller straightening component is used to finely straighten the steel pipe and eliminate residual deformation.

[0007] According to one embodiment of the present invention, the straightening device further includes a straightening base, and the guiding straightening assembly includes a horizontal straightening wheel fixing frame and a vertical straightening wheel fixing frame sequentially arranged on the straightening base along the moving direction of the steel pipe. The horizontal straightening wheel fixing frame is provided with two guide-type horizontal straightening wheels, and the steel pipe passes through the two guide-type horizontal straightening wheels; the vertical straightening wheel fixing frame is provided with two guide-type vertical straightening wheels, and the steel pipe passes through the two guide-type vertical straightening wheels.

[0008] According to one embodiment of the present invention, the roller straightening assembly includes multiple sets of straightening roller mechanisms. Each straightening roller mechanism includes a fixed support, multiple horizontal straightening rollers, and multiple vertical straightening rollers. The fixed support is disposed on the straightening base. The multiple horizontal straightening rollers are arranged symmetrically in pairs and horizontally, and connected to the fixed support. A steel pipe passes through the space between two corresponding horizontal straightening rollers. The multiple vertical straightening rollers are arranged symmetrically in pairs and vertically, and connected to the fixed support. A steel pipe passes through the space between two corresponding vertical straightening rollers.

[0009] According to one embodiment of the present invention, it further includes: The control device is electrically connected to the wire feeding device, the detection device, the defect grinding device, the preheating device, the extrusion molding device, and the wire take-up device.

[0010] According to one embodiment of the present invention, the detection device includes: Four industrial cameras are arranged circumferentially around the outer periphery of the steel pipe and electrically connected to the control device. The industrial cameras are used to acquire image information of the steel pipe and send the image information to the control device. A laser profile sensor is electrically connected to the control device. The laser profile sensor is used to obtain the deviation value between the profile of the steel pipe section and the theoretical outer circle, so as to calculate the roundness deviation, and send the defect location coordinates, defect type and depth or protrusion amplitude to the control device.

[0011] According to one embodiment of the present invention, the detection device further includes: The detection device base is provided with a detection channel, the steel pipe is inserted into the detection channel, and the four industrial cameras are arranged at equal intervals along the circumference in the detection channel. A display is disposed on the upper part of the base of the detection device, and the display is electrically connected to the control device.

[0012] According to one embodiment of the present invention, the defect polishing apparatus includes: Grinding processing device base and grinding actuator; A defect positioning mechanism is disposed on the upper part of the base of the grinding processing device. The defect positioning mechanism is connected to the grinding execution mechanism. The defect positioning mechanism is used to drive the grinding execution mechanism to move to the target position according to the defect position coordinates. The grinding execution mechanism is used to grind the defect position of the steel pipe.

[0013] According to one embodiment of the present invention, the defect grinding treatment apparatus further includes: A rear-mounted inspection camera is installed on the base of the grinding device near the preheating device. The rear-mounted inspection camera is electrically connected to the control device. The rear-mounted inspection camera is used to acquire image information of the repair area of ​​the steel pipe and send the image information of the repair area to the control device.

[0014] According to one embodiment of the present invention, it further includes: A clamping traction device is disposed between the cooling water tank and the take-up device, and the clamping traction device is used to pull the finished umbilical cable toward the take-up device.

[0015] According to one embodiment of the present invention, the clamping traction device includes: The main frame is disposed between the cooling water tank and the take-up device. Two guide limiting plates are provided on the upper part of the main frame. The two guide limiting plates are arranged at intervals along the width direction of the main frame and extend along the length direction of the main frame. The distance between the two guide limiting plates gradually decreases along the length direction of the main frame, then remains constant, and then gradually increases. A traction belt is provided on the main frame, the traction belt is wound around the main frame and rotates cyclically, and the traction belt on the upper part of the main frame is located between the two guide limiting plates; Multiple clamping assemblies are spaced apart along the length of the traction belt. Each clamping assembly includes two clamping seats, which are spaced apart along the width of the traction belt. A groove is provided on one side of each clamping seat facing each other, and an airbag is disposed within the groove. A recess is provided on one side of each airbag facing each other, and the steel pipe is clamped within the recess. A guide roller is rotatably disposed on one side of each clamping seat facing each other, and the guide roller rolls in cooperation with the inner side of the corresponding guide limiting plate. A drive assembly is connected to the traction belt and the main frame, and the drive assembly is used to drive the traction belt to rotate cyclically.

[0016] According to an embodiment of the present invention, a method for extruding and producing steel pipe sheaths for umbilical cables is provided, the method being based on the extrusion and production equipment for steel pipe sheaths for umbilical cables described in any of the preceding claims, the method comprising: The steel pipe is released at a fixed linear speed using a wire-laying device; The steel pipe is initially guided and straightened by the guide straightening assembly, and then finely straightened by the roller straightening assembly to eliminate residual deformation. The roundness parameters of the straightened steel pipe are tested using a testing device. A protective sheath is applied to the outer surface of the steel pipe using an extrusion molding device; The finished umbilical cable is wound up under fixed tension using a take-up device.

[0017] According to an embodiment of the present invention, the step of detecting the roundness parameters of the straightened steel pipe and locating the defect position using a detection device includes: Image information of the steel pipe is acquired using an industrial camera, and the image information is sent to a control device; The deviation between the profile of the steel pipe section and the theoretical outer circle is obtained by a laser profile sensor. The roundness deviation is calculated, and the defect location coordinates, defect type and depth or protrusion amplitude are sent to the control device.

[0018] The above-described one or more technical solutions in the embodiments of the present invention have at least one of the following technical effects: The guide straightening assembly is used to initially guide and straighten the steel pipe, and then the roller straightening assembly is used to finely straighten the steel pipe, eliminating residual local deformation of the steel pipe, further optimizing the straightening effect, and avoiding the small serpentine shape caused by incomplete or excessive straightening when using guide rollers alone.

[0019] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or related technologies, the drawings used in the description of the embodiments or related technologies will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention and are not considered as limitations on this application. Moreover, those skilled in the art can obtain other drawings based on these drawings without creative effort.

[0021] Figure 1 This is a schematic structural diagram of the extrusion molding and production equipment for steel pipe sheaths for umbilical cables provided by the present invention.

[0022] Figure 2 This is one of the schematic structural diagrams of the straightening device provided by the present invention.

[0023] Figure 3 This is the second schematic structural diagram of the straightening device provided by the present invention.

[0024] Figure 4 This is a schematic structural diagram of the detection device provided by the present invention.

[0025] Figure 5 This is a schematic structural diagram of the defect grinding and processing device provided by the present invention.

[0026] Figure 6 This is a schematic structural diagram of the preheating device provided by the present invention.

[0027] Figure 7 This is a schematic structural diagram of the clamping traction device provided by the present invention.

[0028] Figure 8 This is a schematic structural diagram of the two clamping seats provided by the present invention in an unfolded state.

[0029] Figure 9 This is a schematic structural diagram of the two clamping seats provided by the present invention in a clamping state.

[0030] Figure label: 1. Paying-out device; 2. Straightening device; 3. Detection device; 4. Defect grinding and treatment device; 5. Preheating device; 6. Extrusion molding device; 7. Cooling water tank; 8. Clamping traction device; 9. Take-up device; 10. Control device; 20. Straightening base; 21. Horizontal straightening wheel fixing frame; 22. Vertical straightening wheel fixing frame; 23. Fixing bracket; 24. Horizontal straightening roller; 25. Vertical straightening roller; 26. Guided horizontal straightening roller; 27. Guided vertical straightening roller; 31. Detection device base; 32. Detection channel; 33. Display; 40. Grinding device base; 41. Grinding actuator; 42. Defect location mechanism; 51. Heater; 80. Main frame; 81. Guide limit plate; 82. Traction belt; 83. Clamping seat; 84. Airbag; 85. Recess. Detailed Implementation

[0031] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0032] The specific terms used in this specification are for illustrative purposes only and are not intended to limit the illustrated embodiments. For example, expressions such as "same" and "identical" not only indicate a strictly identical state, but also indicate a state with tolerances or differences in the degree of functionality. For example, expressions indicating relative or absolute arrangement such as "in a certain direction," "along a certain direction," "side by side," "perpendicular," "centered on," "concentric," or "coaxial" not only strictly indicate such an arrangement, but also indicate a state of relative displacement by tolerances or angles or distances with the same degree of functionality.

[0033] The terms “center,” “longitudinal,” “lateral,” “length,” “width,” “thickness,” “upper,” “lower,” “front,” “rear,” “left,” “right,” “vertical,” “horizontal,” “top,” “bottom,” “inner,” “outer,” “clockwise,” “counterclockwise,” “axial,” “radial,” and “circumferential” indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the present invention and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting the present invention.

[0034] Furthermore, features specified as "first" or "second" may explicitly or implicitly include one or more of those features. In the description of this invention, unless otherwise stated, "a plurality of" means two or more.

[0035] 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 can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0036] The following is combined Figures 1 to 9 This invention describes the extrusion molding and production equipment and method for steel pipe sheaths for umbilical cables.

[0037] like Figures 1 to 3 As shown, the extrusion molding and production equipment for umbilical cable steel pipe sheaths includes: a wire feeding device 1, a straightening device 2, an inspection device 3, an extrusion molding device 6, and a take-up device 9, arranged sequentially along the moving direction of the steel pipe. The straightening device 2 is used to straighten the steel pipe, the inspection device 3 is used to inspect the roundness of the steel pipe, and the extrusion molding device 6 is used to coat the outer surface of the steel pipe with a sheath layer. The straightening device 2 includes a guide straightening assembly and a roller straightening assembly arranged sequentially along the moving direction of the steel pipe. The guide straightening assembly is used to initially guide and straighten the steel pipe, and the roller straightening assembly is used to finely straighten the steel pipe and eliminate residual deformation. The take-up device 9 is located at the very end of the production line and is used to wind the finished umbilical cable under fixed tension.

[0038] The extrusion molding and production equipment for steel pipe sheaths for umbilical cables provided by the present invention uses a guide and straightening component for initial guidance and straightening of the steel pipe, and then uses a roller straightening component for fine straightening of the steel pipe to eliminate residual local deformation of the steel pipe, further optimize the straightening effect, and avoid the small serpentine shape caused by incomplete or excessive straightening when using guide rollers alone.

[0039] In one embodiment of the present invention, the steel pipe sheath extrusion molding and production equipment for umbilical cables further includes a defect grinding treatment device 4, a preheating device 5, a cooling water tank 7, and a clamping traction device 8. The defect grinding treatment device 4 and the preheating device 5 are sequentially arranged between the detection device 3 and the extrusion molding device 6 along the moving direction of the steel pipe, and the cooling water tank 7 and the clamping traction device 8 are sequentially arranged between the extrusion molding device 6 and the take-up device 9 along the moving direction of the steel pipe.

[0040] In one embodiment of the present invention, the straightening device 2 further includes a straightening base 20, and the guide straightening assembly includes a horizontal straightening wheel fixing frame 21 and a vertical straightening wheel fixing frame 22 arranged sequentially on the straightening base 20 along the moving direction of the steel pipe. The horizontal straightening wheel fixing frame 21 is provided with two guide horizontal straightening wheels 26, and the steel pipe passes through the two guide horizontal straightening wheels 26; the vertical straightening wheel fixing frame 22 is provided with two guide vertical straightening wheels 27, and the steel pipe passes through the two guide vertical straightening wheels 27.

[0041] The guide-type horizontal straightening roller 26 guides, supports, and straightens the steel pipe in the horizontal direction, which can initially constrain the bending trend of the steel pipe in the horizontal plane and reduce the deviation of the steel pipe in the horizontal direction. The guide-type vertical straightening roller 27 guides, supports, and straightens the steel pipe in the vertical direction, which can initially constrain the bending trend of the steel pipe in the vertical plane and reduce the deviation of the steel pipe in the vertical direction. In one embodiment of the present invention, the roller straightening assembly includes multiple sets of straightening roller mechanisms. Each straightening roller mechanism includes a fixed bracket 23, multiple horizontal straightening rollers 24, and multiple vertical straightening rollers 25. The fixed bracket 23 is disposed on the straightening base 20. The multiple horizontal straightening rollers 24 are arranged symmetrically in pairs and horizontally, and are connected to the fixed bracket 23. A steel pipe is inserted between two corresponding horizontal straightening rollers 24. The multiple vertical straightening rollers 25 are arranged symmetrically in pairs and vertically, and are connected to the fixed bracket 23. A steel pipe is inserted between two corresponding vertical straightening rollers 25.

[0042] The straightening roller mechanism straightens the steel pipe from both horizontal and vertical directions. The horizontal straightening rollers 24 are symmetrically arranged in pairs and horizontally, with the steel pipe passing between the corresponding two horizontal straightening rollers 24. The horizontal straightening rollers 24 can apply symmetrical horizontal extrusion force to the steel pipe. The vertical straightening rollers 25 are symmetrically arranged in pairs and vertically, with the steel pipe passing between the corresponding two vertical straightening rollers 25. The vertical straightening rollers 25 can apply symmetrical vertical extrusion force to the steel pipe. Through the sequential extrusion of the above-mentioned multiple sets of straightening roller mechanisms, the residual local bending deformation of the steel pipe after passing through the guide straightening rollers can be eliminated, making the axis of the steel pipe tend to be straight, thereby avoiding the small serpentine bends caused by incomplete or excessive straightening when using the guide straightening rollers alone.

[0043] It should be noted that multiple horizontal straightening wheel fixing frames 21 and vertical straightening wheel fixing frames 22 can be set. Multiple horizontal straightening wheel fixing frames 21 and vertical straightening wheel fixing frames 22 can be set alternately, or the horizontal straightening wheel fixing frames 21 can be set together and multiple vertical straightening wheel fixing frames 22 can be set together.

[0044] It should also be noted that there are multiple straightening roller mechanisms, which are arranged sequentially and at intervals on the straightening base 20 along the moving direction of the steel pipe.

[0045] In one embodiment of the present invention, such as Figure 1As shown, the extrusion molding and production equipment for steel pipe sheaths of umbilical cables also includes a control device 10. The control device 10 is electrically connected to the wire feeding device 1 and can send a speed control signal to the wire feeding device 1 to adjust its feeding speed. The control device 10 is electrically connected to the detection device 3 and can receive the defect location coordinates, defect type, depth, or protrusion amplitude detected by the detection device 3, and generate grinding control commands based on this data. The control device 10 is electrically connected to the defect grinding treatment device 4 and can send grinding control commands to the defect grinding treatment device 4 to move it to the defect location for grinding. The control device 10 is electrically connected to the preheating device 5 and can send a temperature adjustment signal to the preheating device 5 to control its heating temperature. The control device 10 is electrically connected to the extrusion molding device 6 and can send extrusion speed and temperature control signals to the extrusion molding device 6 to adjust the sheath material coating parameters. The control device 10 is electrically connected to the take-up device 9. The control device 10 can send a tension control signal to the take-up device 9 to adjust the winding tension of the take-up device 9.

[0046] The control device 10 collects data in real time, including the pushing speed of the internal anti-pinch column of the straightening device, the real-time curve of the roundness deviation fluctuation in the AI ​​detection device, the cumulative value of the grinding amount in the grinding treatment device, and the traction force of the traction device. When the control device 10 detects that the roundness deviation of a certain section of steel pipe is showing a continuous upward trend, the control device 10 controls the grinding device to increase the grinding frequency and feeds back the traction force data to the extruder to fine-tune the extrusion pressure, ensuring that the sheath layer is fully cooled and shaped before the umbilical cable passes through the traction device.

[0047] The control device 10 collects the operating parameters of each process and establishes a production data traceability archive to realize the full-process tracking of steel pipes from raw materials to finished products. Based on the traction force feedback of the traction device and the roundness detection data of the steel pipe, the control device 10 adjusts the straightening parameters of the straightening device and the extrusion parameters of the extruder to achieve multi-condition collaborative optimization control. When the control device 10 detects that the steel pipe has a serious roundness defect that cannot be repaired by grinding, the control device 10 automatically issues an alarm and marks the defective section to guide subsequent processing.

[0048] In one embodiment of the present invention, such as Figure 1 As shown, the wire feeding device 1 is used to release the steel pipe at a fixed linear speed. The wire feeding device 1 releases the steel pipe at a constant linear speed of 0.5-5 m / min. The tension sensor on the wire feeding device 1 monitors the wire feeding tension in real time. The control device 10 automatically adjusts the wire feeding tension to maintain it within the set range, ensuring that the steel pipe enters the production process under constant tension.

[0049] It should be noted that the steel pipes are 304 or 316L stainless steel pipes with an outer diameter of 10-60mm and a wall thickness of 0.8-3mm.

[0050] In one embodiment of the present invention, such as Figure 1 and Figure 4 As shown, the detection device 3 includes four industrial cameras and a laser contour sensor. Of course, the number of industrial cameras is not limited to this and can be determined according to actual needs. The four industrial cameras are circumferentially spaced around the outer periphery of the steel pipe, arranged symmetrically in pairs about the center of the steel pipe, and located on the extensions of two diameters of the steel pipe, with the two diameters perpendicular to each other. The four industrial cameras are electrically connected to the control device 10. The industrial cameras are used to acquire image information of the steel pipe and send the image information to the control device 10. By setting up four industrial cameras, a 360° panoramic image of the outer surface of the steel pipe can be captured.

[0051] The control device 10 has a built-in deep learning model, which is trained in advance on thousands of steel pipe sample images with labeled defect types. After receiving the image information of the steel pipe, the control device 10 can accurately identify common defect types such as elliptical deformation, local dents and bumps, scratches, and indentations through the learning model. When a defect matching the characteristics is identified, the control device 10 will issue an alarm.

[0052] The laser profile sensor is electrically connected to the control device 10. The laser profile sensor captures a 360° panoramic image and scans the profile of the steel pipe to obtain the deviation between the profile of the steel pipe cross-section and the theoretical outer circle. It then calculates the roundness deviation (a deviation ≤ 0.1mm is acceptable) and sends the defect location coordinates, defect type, and depth or protrusion amplitude to the control device 10. Upon receiving the deviation value, the control device 10 determines whether the roundness meets the acceptable requirement of a deviation ≤ 0.1mm and records the location of any non-compliant defects.

[0053] The control device 10 controls the defect positioning mechanism 42 to drive the grinding execution mechanism 41 to move to the target position according to the defect position coordinates, and automatically oriented grinding the defect position of the steel pipe. The control device 10 converts the defect position coordinates into a drive signal and sends it to the defect positioning mechanism 42. The defect positioning mechanism 42 drives the grinding execution mechanism 41 to move according to the drive signal, so that the grinding execution mechanism 41 is aligned with the defect position. After contacting the surface of the steel pipe, the grinding execution mechanism 41 removes material from the defect position by rotating or reciprocating, thereby reducing the protrusions or depressions on the surface of the steel pipe and making the roundness of the steel pipe surface approach the qualified range of deviation ≤0.1mm.

[0054] In one embodiment of the present invention, such as Figure 1 and Figure 4As shown, the detection device 3 also includes a detection device base 31 and a display 33. The detection device base 31 is provided with a detection channel 32. The steel pipe passes through the detection channel 32. Four industrial cameras are arranged at equal intervals along the circumference in the detection channel 32. The four industrial cameras can simultaneously acquire images of the outer surface of the steel pipe from four directions that are 90° apart from each other, so as to cover the entire circumference of the steel pipe and reduce the blind spot of image acquisition.

[0055] The display 33 is located on the upper part of the base 31 of the detection device. The display 33 is electrically connected to the control device 10. The control device 10 distributes the steel pipe image information received from the four industrial cameras to different display areas of the display 33 for partitioned display, so as to simultaneously present the surface condition of the steel pipe in four circumferential directions on the same screen. This allows the operator to observe real-time images of the steel pipe at various angles without getting close to the detection device. By observing the steel pipe surface images displayed in each partition on the display 33, the operator can compare the straightness performance of the steel pipe in different circumferential directions, thereby judging the working status of the straightening device.

[0056] Existing technologies mainly rely on manual sampling inspection, resulting in weak quality assurance capabilities. This invention employs an online inspection scheme combining machine vision and deep learning models to achieve complete online inspection and precise location of surface defects in steel pipes, thereby improving production efficiency and product quality.

[0057] In one embodiment of the present invention, such as Figure 1 and Figure 5 As shown, the defect grinding treatment device 4 is used to grind the surface defects of the steel pipe that need to be repaired. The defect grinding treatment device 4 includes a grinding treatment device base 40, a grinding execution mechanism 41, and a defect positioning mechanism 42. The defect positioning mechanism 42 is a six-axis robotic arm. The fixed end of the six-axis robotic arm is fixed to the upper part of the grinding treatment device base 40. The end of the six-axis robotic arm is connected to the grinding execution mechanism 41. The six-axis robotic arm is used to drive the grinding execution mechanism 41 to move to the target position according to the defect position coordinates. The target position is determined according to the defect position coordinates of the steel pipe. Through the coordinated rotation of its six joints, the six-axis robotic arm can freely position its end in the three-axis direction and attitude angle in space, thereby adapting to defects with different circumferential angles and axial positions on the surface of the steel pipe.

[0058] The grinding actuator 41 is used to grind the defect location of the steel pipe. After the grinding actuator 41 moves to the target position, the control device 10 automatically calculates the grinding amount, grinding position and grinding path according to the defect depth, and controls the grinding actuator 41 to grind the steel pipe. The control device 10 converts the defect depth value into the grinding removal thickness, and generates a continuous grinding trajectory according to the geometry of the defect, so that the grinding actuator 41 grinds the defect area along the trajectory in sequence, thereby grinding the protrusion at the defect location flat or the surrounding area of ​​the depression to a smooth transition with the bottom of the depression, so that the roundness of the steel pipe surface after grinding is close to the qualified range.

[0059] In one embodiment of the present invention, the defect grinding processing device 4 further includes a rear-mounted detection camera. The rear-mounted detection camera is disposed on the side of the grinding processing device base 40 near the preheating device 5. The rear-mounted detection camera is electrically connected to the control device 10. The rear-mounted detection camera is used to acquire image information of the repair area of ​​the steel pipe and send the image information of the repair area to the control device 10. The AI ​​model in the control device 10 re-checks and confirms the image information of the repair area. The AI ​​model compares the image of the repair area with the preset qualified surface features to determine whether there are residual defects or new scratches on the surface after grinding, so as to confirm whether the repair area has reached the state that can enter the subsequent preheating process.

[0060] Existing technologies require manual grinding after machine shutdown, which is inefficient and results in inconsistent quality. This invention achieves automatic defect identification, automatic and precise positioning for grinding, and automatic re-inspection after grinding in a closed-loop control system without stopping the entire production line, thus improving both production efficiency and product quality.

[0061] Furthermore, guide wheels are provided at both ends of the grinding treatment device base 40, and two defect positioning mechanisms 42 are provided. The two defect positioning mechanisms 42 are located between the two guide wheels. The guide wheels are used to support and guide the steel pipe. The two guide wheels are in rolling contact with the steel pipe at both ends, so that the steel pipe maintains a horizontal posture above the grinding treatment device base 40 and reduces the deformation of the steel pipe during the grinding process.

[0062] Furthermore, in order to reduce the dust generated during the grinding process, a dust removal port is provided on the base 40 of the grinding device, and a dust removal device is provided at the bottom of the base 40 of the grinding device. The dust removal device is connected to the dust removal port. The dust removal device is used to draw the dust generated during the grinding process into the interior of the dust removal device through the dust removal port. The fan inside the dust removal device rotates to generate negative pressure, which causes the dust-laden airflow near the dust removal port to enter the filter chamber of the dust removal device along the pipe. The dust is intercepted by the filter material and collected in the dust collection box, thereby reducing the suspended particulate matter that drifts into the environment around the equipment.

[0063] In one embodiment of the present invention, such as Figure 1and Figure 6 As shown, the preheating device 5 is used to heat the steel pipe, and the preheating temperature is controlled within the range required by the forming process of the steel pipe sheath material. The steel pipe is inserted into the preheating device 5, which is equipped with multiple heaters 51. The multiple heaters 51 heat the steel pipe from different angles.

[0064] In one embodiment of the present invention, such as Figure 1 As shown, the extrusion molding device 6 is used to uniformly coat the outer surface of the steel pipe with a polymer sheath material to form a sheath layer. The cooling water tank 7 is used to cool the steel pipe in sections after the sheath layer is coated, so that the sheath layer can be shaped and solidified.

[0065] In one embodiment of the present invention, the clamping traction device includes a main frame 80, a traction belt 82, multiple clamping assemblies, and a drive assembly. The main frame 80 is disposed between the cooling water tank 7 and the take-up device 9. Two guide limiting plates 81 are provided on the upper part of the main frame 80. The two guide limiting plates 81 are arranged at intervals along the width direction of the main frame 80 and extend along the length direction of the main frame 80. The distance between the two guide limiting plates 81 gradually decreases along the length direction of the main frame 80, then remains constant, and then gradually increases. An inlet contraction section, a middle parallel section, and an outlet expansion section are formed between the two guide limiting plates 81. The inlet contraction section can gradually guide the clamping assemblies entering between the two guide limiting plates 81, so that the two clamping seats 83 move closer to each other to clamp the steel pipe between the two airbags 84. The middle parallel section can maintain a stable lateral spacing between the clamping assemblies. The outlet expansion section can gradually separate the clamping assemblies when they leave, so that the two clamping seats 83 move away from each other to release the clamping of the steel pipe.

[0066] The traction belt 82 is installed on the main frame 80. The traction belt 82 is wrapped around the main frame 80 and rotates cyclically. The traction belt 82 on the upper part of the main frame 80 is located between two guide limiting plates 81. The movement direction of the traction belt 82 on the upper part of the main frame 80 is the same as the movement direction of the steel pipe. The traction belt 82 drives the clamping assembly on it to move along the inner side of the guide limiting plate 81, so that the clamping assembly gradually clamps the steel pipe during the movement, then maintains the clamped state, and then gradually releases the steel pipe.

[0067] Multiple sets of clamping components are spaced apart along the length of the traction belt 82. Preferably, there are 3-6 clamping components, and the spacing between two adjacent clamping components is equal, so that the steel pipe is supported by multiple spaced clamping points during the traction process, reducing the suspended length of the steel pipe between adjacent clamping points.

[0068] The clamping assembly includes two clamping seats 83, which are spaced apart along the width of the traction belt 82 and arranged symmetrically. A groove is provided on one side of each clamping seat 83 facing each other, and an airbag 84 is placed within the groove. A recess 85 is provided on one side of each airbag 84 facing each other, and a steel pipe is clamped within the recess 85. The shape of the recess 85 conforms to the outer surface of the steel pipe, increasing the contact area between the airbag 84 and the steel pipe. When the two airbags 84 are close together, they can clamp the steel pipe 360° circumferentially. After inflation, the airbag 84 undergoes elastic deformation, and the inner wall of its recess 85 wraps around the outer circumferential surface of the steel pipe, ensuring that the clamping force is evenly distributed along the circumference of the steel pipe and reducing localized indentations on the steel pipe surface.

[0069] Preferably, the inner side of the airbag 84 is configured as a flexible wear-resistant clamping surface with a composite pattern. The raised and recessed structure of the composite pattern can increase the friction coefficient between the airbag 84 and the steel pipe surface, while reducing the direct contact area between the airbag 84 and the steel pipe, so that the friction force during clamping can reduce the wear of the airbag 84 surface while maintaining sufficient traction force.

[0070] Furthermore, the airbag 84 and the clamping seat 83 are detachably connected. By replacing the airbag 84 with different inner diameter sizes, the same clamping seat 83 can be used to clamp steel pipes with different outer diameters. The airbag 84 and the clamping seat 83 can be connected by bolts, snap-fit ​​connections, or other detachable connection methods.

[0071] Two clamping seats 83 are rotatably provided with guide rollers on one side facing each other. The guide rollers roll in cooperation with the inner side of the corresponding guide limiting plate 81. When the guide rollers roll along the inner surface of the guide limiting plate 81, the lateral thrust on the guide rollers is transmitted to the clamping seats 83, so that the lateral distance between the two clamping seats 83 changes with the change of the distance between the guide limiting plates 81.

[0072] The drive assembly is connected to the traction belt 82 and the main frame 80. The drive assembly is used to drive the traction belt 82 to rotate cyclically, so that multiple sets of clamping assemblies rotate cyclically along the traction belt 82, thereby achieving the traction of the steel pipe. The drive assembly is a motor or a combination of a motor and a transmission roller.

[0073] During traction, the guide roller contacts the inner side of the guide limiting plate 81. Guided by the guide limiting plate 81, the two clamping seats 83 move closer to each other to clamp the steel pipe between the two airbags 84, or move the two clamping seats 83 away from each other to release the clamping of the steel pipe. When the clamping assembly moves with the traction belt 82 to the inlet contraction section of the guide limiting plate 81, the distance between the two clamping seats 83 is larger, and the steel pipe enters between the recesses 85 of the two airbags 84. When the clamping assembly moves to the middle parallel section of the guide limiting plate 81, the distance between the two clamping seats 83 gradually decreases to a set value, and the recesses 85 of the airbags 84 contact the surface of the steel pipe and apply clamping force. When the clamping assembly moves to the outlet expansion section of the guide limiting plate 81, the distance between the two clamping seats 83 gradually increases, and the recesses 85 of the airbags 84 disengage from the surface of the steel pipe.

[0074] During traction, the control device 10 calculates the pre-inflation pressure of each airbag 84 based on the actual outer diameter of the umbilical cable, ensuring that each clamping airbag 84 simultaneously applies uniform radial pressure to the umbilical cable to provide stable traction. Because the umbilical cable surface experiences balanced force across 360°, even with fluctuations in traction force, the cross-section of the hollow steel pipe always maintains its roundness, completely eliminating the risk of flattening and deformation compared to traditional tracked or roller-type traction methods. The traction speed is adjusted in real-time by the control device 10 according to the production line speed requirements.

[0075] It should be noted that the towing belt 82 is made of a flexible material, such as rubber or other flexible materials, in which case the clamping seat 83 is fixedly connected to the towing belt 82. Of course, when the towing belt 82 is a track or a rigid towing structure, the towing belt 82 is provided with a groove, and the clamping seat 83 is provided with a locking part. The locking part is slidably engaged within the groove, allowing the two clamping seats 83 to move closer or further apart through the sliding engagement of the locking part and the groove. Furthermore, a compression spring is provided between the two clamping seats 83. When the two clamping seats 83 move closer together, the spring is further compressed; when the two clamping seats 83 move further apart, the spring returns to its initial length.

[0076] The present invention also provides an extrusion molding and production method for steel pipe sheaths for umbilical cables, the method being based on the extrusion molding and production equipment for steel pipe sheaths for umbilical cables described in any of the above embodiments, the method comprising: The steel pipe is released at a fixed linear speed via the wire-laying device 1; The steel pipe is initially guided and straightened by the guide straightening assembly, and then finely straightened by the roller straightening assembly to eliminate residual deformation. The roundness parameter of the straightened steel pipe is detected by the detection device 3. A protective sheath is applied to the outer surface of the steel pipe using an extrusion molding device 6; The finished umbilical cable is wound up with fixed tension using the take-up device 9.

[0077] In one embodiment of the present invention, the method for extruding and producing steel pipe sheaths for umbilical cables further includes: The defect grinding treatment device 4 grinds the surface defects of the steel pipe that need to be repaired. The steel pipe is heated by the preheating device 5; The steel pipe covered with the sheath layer is cooled in sections by cooling water tank 7 so that the sheath layer can be shaped and solidified.

[0078] In one embodiment of the present invention, the steps of initially guiding and straightening the steel pipe using a guide straightening assembly, and then finely straightening the steel pipe using a roller straightening assembly to eliminate residual deformation include: The horizontal straightening roller 26 guides, supports, and straightens the steel pipe in the horizontal direction, while the vertical straightening roller 27 guides, supports, and straightens the steel pipe in the vertical direction. The straightening roller mechanism straightens the steel pipe from both the horizontal and vertical directions to eliminate residual local deformation of the steel pipe. In one embodiment of the present invention, the steps of detecting the roundness parameters of the straightened steel pipe and locating the defect position using the detection device 3 include: The image information of the steel pipe is acquired by an industrial camera and sent to the control device 10; The deviation between the profile of the steel pipe section and the theoretical outer circle is obtained by the laser profile sensor. The roundness deviation is calculated, and the coordinates of the defect location, the defect type and depth or the bulge amplitude are sent to the control device 10.

[0079] In one embodiment of the present invention, the method for extruding and producing steel pipe sheaths for umbilical cables further includes: The drive assembly drives the traction belt 82 to rotate cyclically, causing multiple sets of clamping assemblies to rotate cyclically along the traction belt 82, thereby achieving the traction of the steel pipe; During traction, the guide roller contacts the inner side of the guide limiting plate 81. Guided by the guide limiting plate 81, the two clamping seats 83 move closer to each other to clamp the steel pipe between the two airbags 84, or move the two clamping seats 83 away from each other to release the clamping of the steel pipe. When the clamping assembly moves with the traction belt 82 to the inlet contraction section of the guide limiting plate 81, the distance between the two clamping seats 83 is larger, and the steel pipe enters between the recesses 85 of the two airbags 84. When the clamping assembly moves to the middle parallel section of the guide limiting plate 81, the distance between the two clamping seats 83 gradually decreases to a set value, and the recesses 85 of the airbags 84 contact the surface of the steel pipe and apply clamping force. When the clamping assembly moves to the outlet expansion section of the guide limiting plate 81, the distance between the two clamping seats 83 gradually increases, and the recesses 85 of the airbags 84 disengage from the surface of the steel pipe.

[0080] Finally, it should be noted that the above embodiments are only for illustrating the present invention and not for limiting the present invention. Although the present invention has been described in detail with reference to the embodiments, those skilled in the art should understand that various combinations, modifications, or equivalent substitutions of the technical solutions of the present invention do not depart from the spirit and scope of the technical solutions of the present invention and should be covered within the scope of the claims of the present invention.

Claims

1. An extrusion molding and production equipment for steel pipe sheaths for umbilical cables, characterized in that, include: Along the direction of movement of the steel pipe, the following are arranged in sequence: Wire feeding device (1); Straightening device (2) is used to straighten steel pipes; The detection device (3) is used to detect the roundness of the steel pipe; Extrusion molding apparatus (6) for covering the outer surface of a steel pipe with a sheath layer; and Take-up device (9); The straightening device (2) includes a guide straightening component and a roller straightening component arranged sequentially along the moving direction of the steel pipe. The guide straightening component is used to initially guide and straighten the steel pipe, and the roller straightening component is used to finely straighten the steel pipe and eliminate residual deformation.

2. The extrusion molding and production equipment for steel pipe sheaths for umbilical cables according to claim 1, characterized in that, The straightening device (2) further includes a straightening base (20). The guide straightening assembly includes a horizontal straightening wheel fixing frame (21) and a vertical straightening wheel fixing frame (22) arranged sequentially on the straightening base (20) along the moving direction of the steel pipe. The horizontal straightening wheel fixing frame (21) is provided with two guide horizontal straightening wheels (26), and the steel pipe passes through the two guide horizontal straightening wheels (26). The vertical straightening wheel fixing frame (22) is provided with two guide vertical straightening wheels (27), and the steel pipe passes through the two guide vertical straightening wheels (27).

3. The extrusion molding and production equipment for steel pipe sheaths for umbilical cables according to claim 2, characterized in that, The roller straightening assembly includes multiple sets of straightening roller mechanisms. Each straightening roller mechanism includes a fixed bracket (23), multiple horizontal straightening rollers (24), and multiple vertical straightening rollers (25). The fixed bracket (23) is mounted on the straightening base (20). The multiple horizontal straightening rollers (24) are arranged symmetrically in pairs and horizontally, and are connected to the fixed bracket (23). The steel pipe passes between the corresponding two horizontal straightening rollers (24). The multiple vertical straightening rollers (25) are arranged symmetrically in pairs and vertically, and are connected to the fixed bracket (23). The steel pipe passes between the corresponding two vertical straightening rollers (25).

4. The extrusion molding and production equipment for steel pipe sheaths for umbilical cables according to claim 1, characterized in that, Also includes: The control device (10) is electrically connected to the wire feeding device (1), the detection device (3), the defect grinding device (4), the preheating device (5), the extrusion molding device (6), and the wire take-up device (9).

5. The extrusion molding and production equipment for steel pipe sheaths for umbilical cables according to claim 4, characterized in that, The detection device (3) includes: Four industrial cameras are arranged circumferentially around the outer periphery of the steel pipe and electrically connected to the control device (10). The industrial cameras are used to acquire image information of the steel pipe and send the image information to the control device (10). A laser profile sensor is electrically connected to the control device (10). The laser profile sensor is used to obtain the deviation value between the profile of the steel pipe section and the theoretical outer circle, so as to calculate the roundness deviation, and send the defect location coordinates, defect type and depth or protrusion amplitude to the control device (10).

6. The extrusion molding and production equipment for steel pipe sheaths for umbilical cables according to claim 5, characterized in that, The detection device (3) further includes: The detection device base (31) is provided with a detection channel (32), the steel pipe is inserted into the detection channel (32), and the four industrial cameras are arranged at equal intervals along the circumference in the detection channel (32). A display (33) is disposed on the upper part of the base (31) of the detection device, and the display (33) is electrically connected to the control device (10).

7. The extrusion molding and production equipment for steel pipe sheaths for umbilical cables according to any one of claims 2 to 6, characterized in that, The defect polishing device (4) includes: Grinding processing device base (40) and grinding actuator (41); A defect positioning mechanism (42) is set on the upper part of the base (40) of the grinding processing device. The defect positioning mechanism (42) is connected to the grinding execution mechanism (41). The defect positioning mechanism (42) is used to drive the grinding execution mechanism (41) to move to the target position according to the defect position coordinates. The grinding execution mechanism (41) is used to grind the defect position of the steel pipe.

8. The extrusion molding and production equipment for steel pipe sheaths for umbilical cables according to claim 7, characterized in that, The defect grinding and treatment device (4) also includes: A rear-mounted inspection camera is installed on the side of the grinding and processing device base (40) near the preheating device (5). The rear-mounted inspection camera is electrically connected to the control device (10). The rear-mounted inspection camera is used to acquire image information of the repair area of ​​the steel pipe and send the image information of the repair area to the control device (10).

9. The extrusion molding and production equipment for steel pipe sheaths for umbilical cables according to any one of claims 1 to 6, characterized in that, Also includes: A clamping traction device (8) is disposed between the cooling water tank (7) and the take-up device (9). The clamping traction device (8) is used to pull the finished umbilical cable toward the take-up device (9).

10. The extrusion molding and production equipment for steel pipe sheaths for umbilical cables according to claim 9, characterized in that, The clamping traction device (8) includes: The main frame (80) is located between the cooling water tank (7) and the take-up device (9). The upper part of the main frame (80) is provided with two guide limiting plates (81). The two guide limiting plates (81) are arranged at intervals along the width direction of the main frame (80) and extend along the length direction of the main frame (80). The distance between the two guide limiting plates (81) gradually decreases along the length direction of the main frame (80), then remains unchanged, and then gradually increases. A traction belt (82) is provided on the main frame (80). The traction belt (82) is wrapped around the main frame (80) and rotates cyclically. The traction belt (82) on the upper part of the main frame (80) is located between the two guide limiting plates (81). Multiple clamping assemblies are spaced apart along the length of the traction belt (82). Each clamping assembly includes two clamping seats (83) spaced apart along the width of the traction belt (82). A groove is provided on one side of each clamping seat (83) facing each other, and an airbag (84) is provided in the groove. A recess (85) is provided on one side of each airbag (84) facing each other, and the steel pipe is clamped in the recess (85). A guide roller is rotatably provided on one side of each clamping seat (83) facing each other, and the guide roller rolls in cooperation with the inner side of the corresponding guide limiting plate (81). A drive assembly is connected to the traction belt (82) and the main frame (80), and the drive assembly is used to drive the traction belt (82) to rotate cyclically.

11. A method for extruding and producing a steel pipe sheath for umbilical cables, the method being based on the extrusion molding and production equipment for steel pipe sheaths for umbilical cables according to any one of claims 1 to 10, characterized in that, The method includes: The steel pipe is released at a fixed linear speed by the wire-laying device (1); The steel pipe is initially guided and straightened by the guide straightening assembly, and then finely straightened by the roller straightening assembly to eliminate residual deformation. The roundness parameters of the straightened steel pipe are tested by the testing device (3); A protective sheath is applied to the outer surface of the steel pipe using an extrusion molding device (6); The finished umbilical cable is wound up under fixed tension using the take-up device (9).

12. The extrusion molding and production method of steel pipe sheath for umbilical cables according to claim 11, characterized in that, The step of detecting the roundness parameter of the straightened steel pipe using the detection device (3) includes: Image information of the steel pipe is acquired by an industrial camera and the image information is sent to the control device (10). The deviation between the profile of the steel pipe section and the theoretical outer circle is obtained by the laser profile sensor, the roundness deviation is calculated, and the defect location coordinates, defect type and depth or protrusion amplitude are sent to the control device (10).

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