Piping manufacturing jig

Abstract

When manufacturing large or complex-shaped pipes for use on ships, factory equipment, etc., conventional methods are inefficient and difficult to maintain precision. In particular, adjusting the horizontal level and flange angle is time-consuming, and there is a lack of jigs that can accommodate a variety of flange shapes. [Solution] We provide a jig that can slide and rotate on the bed, making it easy to adjust the position of the pipe. In addition, a special flange plate can accommodate a variety of flange shapes, enabling efficient pipe production without the need to measure levels or angles. The flange plate can slide and rotate on the bed, and can accommodate flanges of different shapes and sizes. This significantly improves work efficiency while maintaining precision when producing large or complex pipes.

Description

[Technical Field]

[0001] This invention relates to a jig used on ships and other vessels that can manufacture pipes of various shapes. Its functional and effective design contributes to improving work efficiency and safety and convenience. [Background technology]

[0002] In the case of a straight pipe as shown in Figure 1, conventional pipe manufacturing involves a process in which the pipe is placed on a surface plate and flanges are temporarily welded while maintaining a horizontal level. 1. Place the tube on the surface plate Place two V-blocks on the surface plate, place the pipe on them, and maintain the surface plate and the pipe at a horizontal level. 2. Temporary welding of flanges A flange is temporarily fastened to one end of the pipe (side 1). After temporarily welding side A of the flange and pipe, a flange square is used to check the right angle, and then side B is temporarily welded. Next, the pipe is rotated 90 degrees, the flange square is used to check the right angle, and sides C and D are temporarily welded. 3. Maintaining horizontal level Then, use a square to check and maintain the horizontal level between the surface plate and the pipe as shown in the side view. 4.Temporarily fasten the flange on the other end (side 2) Meanwhile, temporarily attach the flange to side 2 of the other end of the pipe, check the dimensions, and use the square again to maintain the horizontal level between the surface plate and the pipe. After tack welding side A using the same process as side 1, use the flange square to check the right angle and tack weld side B. Next, rotate the pipe 90 degrees, check the right angle with the flange square, and tack weld sides C and D. After that, use the square to maintain the horizontal level between the surface plate and the pipe, as shown in the side view. This process requires extensive use of squares to ensure the pipe is level and the flange is square, which allows for precision tack welding, but the large amount of manual adjustment required makes it inefficient and time-consuming.

[0003] The conventional pipe manufacturing process for the bent pipe shown in Figure 2 is as follows. 1. Place the tube on the surface plate Place three V-blocks on the surface plate, place the pipe on them, and maintain the level between the surface plate and the pipe. Check the level with a square. 2. Temporarily weld one flange of the pipe A flange is attached to one end of the pipe (side 1). After tack welding side A of the flange and pipe, a flange square is used to check the right angle and side B is tack welded. Next, the flange square is placed on top of the pipe to check the angle, and sides C and D are tack welded. 3. Maintaining horizontal level Then, use a square as shown in the side view to maintain the horizontal level between the surface plate and the pipe. Check that the horizontal level is maintained properly. 4. Temporarily weld the two flanges of the pipe Meanwhile, attach a flange to the other end of the pipe (side 2), check the dimensions, and use a square to maintain the level between the surface plate and the pipe. After tack welding side A, use the flange square to check the right angle and tack weld side B. Next, rotate the pipe 90 degrees, check the right angle with the flange square, and tack weld sides C and D. After that, use a square to maintain the level between the surface plate and the pipe, as shown in the side view. 5.Bent pipe There are various types of bent pipes as shown in FIG. 3, and any type can be manufactured by the method described above and shown in FIG. In the conventional method, flanges are temporarily attached to each end of the pipe, and a flange square is used to maintain the right angles and horizontal level as work proceeds. Compared to straight pipes, the way the angle is set is important for curved pipes, and a distinctive feature of this method is that a flange square is used on the top of the pipe to adjust the angle. In addition, to ensure precision, the process of maintaining horizontality using a square is repeated. While the conventional method requires multiple manual adjustments, making it less efficient, it is flexible enough to handle complex bent pipes.

[0004] The bends shown in Figure 3 allow for changes in direction in piping and pipelines for fluids and gases. It is important to select an appropriate bend shape depending on the inner diameter of the pipe, the type of material flowing, and the flow speed and pressure. 1.90 degree standard bend The diagram on the top left shows a standard 90-degree right-angle bend. This type is the most common and is used when a fluid or gas needs to pass at a right angle. It is often used to save installation space. 2. Right-angle compound bends The diagram on the top right shows a compound bend shape that includes a 90-degree right-angle bend and additional turns. This is used when a pipeline needs to avoid multiple obstacles or when a complex layout is required. 3. Diagonal bend The diagram on the bottom left shows a diagonal bend. These are often bent at a 45-degree angle and are used to keep fluids flowing more smoothly. They create less friction than right-angle bends, which helps keep fluids flowing more smoothly. 4. S-shaped bend The diagram on the bottom right shows an S-shaped bend. It is used when a pipe needs to move up and down, or change between horizontal and vertical. This shape is useful for avoiding changes in terrain and other obstacles.

[0005] As such, the manufacturing of straight and bent pipes requires multiple temporary welding processes and the use of a square to create right angles while maintaining a horizontal level, which is very time-consuming.In addition, it is difficult to accurately attach the flange and pipe, and creating the right angle for bent pipes in particular has been a challenge.

[0006] Furthermore, the pipe welding jig described in Patent Document 1 allows the relative position and angle of both parts to be fixed as desired when welding a pipe fitting to a piping tube.In order to solve the conventional problem of measuring the height and angle of the bent part of the tube using a height gauge, protractor, etc., or using a three-dimensional measuring machine, the jig has a mechanism that allows movement in the X and Y directions and horizontal rotation, and discloses a technology that reduces the labor required to check the dimensions, shape, and accuracy using a three-dimensional measuring machine or a general-purpose measuring machine.

[0007] In other words, the piping welding jig described in Patent Document 1 can fix the relative position and angle of the piping tube and pipe fitting as desired, but is not suitable for handling large piping or complex bent pipes, and there is a demand for a jig that can be used particularly for large piping on ships, etc.

[0008] [Prior art documents] [Patent documents]

[0009] [Patent Document 1] Japanese Patent Application Laid-Open No. 11-58074 (Specification

[0003] -

[0004] , Figure 1) Summary of the Invention [Problem to be solved by the invention]

[0010] However, when handling large piping, such as that used on ships, a jig for manufacturing small items, such as that shown in Patent Document 1, is not suitable, and Patent Document 1 has limitations in that it is only suitable for applications where measurements are taken on-site and manufacturing is required. The jig shown in Patent Document 1 is not suitable for applications where jigs can be used for pipe sizes from 15A to 125A and lengths of 5.5m, such as those used on ships, and where 10 types of flanges, from 5K-15A to 5K-125A, can be attached. In other words, it is insufficient to handle large piping and a variety of flanges, and there is a need for a jig that can handle piping, particularly those used on ships, from 15A to 125A and lengths of 5.5m.

[0011] In particular, there is no other jig for pipe manufacturing that improves work efficiency while maintaining the precision of pipe manufacturing, and increases safety and convenience. This invention was made possible through the ingenuity of the inventor, who came up with an improved technology that is superior to conventional products.

[0012] The present invention improves the flexibility and efficiency of piping fabrication by providing a jig that can slide and rotate on a bed, and by using special flange plates, it can accommodate a variety of flange shapes, making piping fabrication work more efficient.

[0013] Compared to conventional technologies, the present invention offers greater flexibility and efficiency than conventional technologies by accommodating a variety of flange shapes, specializing in designs for large pipes, and incorporating innovations to reduce frictional resistance. Furthermore, by eliminating the need for measurement, the present invention significantly contributes to improving work efficiency on-site. Specifically, the following points are compared: -Supports a variety of flange shapes The jig of the present invention differs from conventional techniques in that it can accommodate a variety of flange shapes, including square flanges and specially shaped flanges, and has the flexibility to accommodate a variety of piping. On the other hand, conventional techniques often focus on specific shapes and sizes, and are not adequately able to accommodate a variety of flange shapes. - Flat steel is used to reduce friction resistance The present invention uses flat steel to reduce frictional resistance during sliding, and this design improves the smoothness of movement and the durability of the jig. The prior art does not disclose the use of such materials. Piping for large ships The present invention is specialized for large piping in terms of both size and length, and in this respect, while the conventional technology is suited to small-scale piping fabrication, the technology of the present invention is optimized for larger-scale facilities and ship construction. No need to measure levels or angles The present invention eliminates the need to measure levels and angles, significantly improving work efficiency. In contrast, the prior art requires measurement work and includes a process using measuring tools, making it less efficient. [Means for solving the problem]

[0014] In order to solve the above problems, the present invention provides the following. (1) Slide movement and rotation function The jig of this invention allows the flange plate to slide and rotate on the bed, making it easy to adjust the position of the pipe and improving the efficiency of manufacturing short and long pipes.Furthermore, flat steel is used to reduce frictional resistance during sliding, and countersunk screws are used to prevent distortion and deformation of the base.

[0015] (2) Various flange installation By using a special flange plate, flanges of various shapes (such as square flanges and circular flanges) can be attached, and it can also accommodate different piping shapes, especially hydraulic pipes. In particular, the ability to manufacture pipes using three different flanges - 5K, 10K, and square flanges (210K) - allows for compatibility with a variety of piping systems, improving flexibility. For example, compatibility with circular flanges, square flanges, and special-shaped flanges further improves work efficiency on site. The flanges may be 16K, 20K, 30K, etc., used for engine starters and reducers, or hydraulic pipe flanges used for winches, hatch covers, deck cranes, etc. Generally, 70% or more of the entire ship is made up of 5K and 10K flanges.

[0016] (3) Efficiency without measurement There is no need to measure the level or flange angle, allowing for efficient work while maintaining the accuracy of piping production.

[0017] (4) Flange plate bolt holes The design allows the use of square flanges for hydraulic pipes using the bolt holes, making it possible to accommodate flanges of various shapes and sizes, including square flanges, and expanding the range of applications for hydraulic pipe manufacturing. This means that different flange shapes can be used in a variety of piping manufacturing, such as for ships and hydraulic systems, contributing to work efficiency and cost reduction.

[0018] According to the present invention, it is possible to provide an efficient jig design that is capable of sliding and rotating flange plates, is compatible with a variety of flange shapes, and is suitable for manufacturing large-scale piping. [Effects of the Invention]

[0019] The present invention can flexibly accommodate the production of piping for large ships and piping of various shapes, contributing to improved work efficiency, safety, and convenience. [Brief explanation of the drawings]

[0020] [Figure 1] FIG. 1 is a diagram for explaining a conventional working method for manufacturing a straight pipe. [Figure 2] FIG. 10 is a diagram for explaining a conventional method for manufacturing a curved pipe. [Figure 3] FIG. 10 is a diagram for explaining types of bent pipes. [Figure 4] 1A and 1B are diagrams for explaining a pipe manufacturing method using the piping manufacturing jig (L-shaped) of the present invention. [Figure 5] 1A and 1B are diagrams for explaining a pipe manufacturing method using the piping manufacturing jig (L-shaped) of the present invention. [Figure 6] FIG. [Figure 7] FIG. [Figure 8] FIG. [Figure 9] FIG. [Figure 10] FIG. [Figure 11] 1 is a diagram for explaining a pipe manufacturing method using the piping manufacturing jig (T-type) of the present invention. [Figure 12] FIG. [Figure 13] FIG. [Figure 14] FIG. BEST MODE FOR CARRYING OUT THE INVENTION

[0021] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0022] 4 is a diagram for explaining a pipe manufacturing method using the piping manufacturing jig (L-shaped) of the present invention, with the upper half being a side view and the lower half being a plan view. There are flange plates on sides A and B, and stoppers are also located.

[0023] The procedure for making a straight pipe is as follows: (0) Placing the pipe: Place the straight pipe on the pipe holder on the surface plate. (1) Fixing the B-side flange plate: After the flange plate located on the B side moves to the stopper abutment position, it is fastened to the straight pipe with an M20 fixing bolt. (2) Fixing the flange plate on side A: After the flange plate on side A is moved to the dimensional position, it is fastened to the straight pipe with an M20 fixing bolt. (3) Level (height) measurement: After attaching the temporary flange to the flange plate, measure the level (height). (4) Adjusting the height of the loading platform: After adjusting the height of the loading platform to match the measured dimensions, install flanges on sides A and B on the bed. (5) Inserting the flange: Remove the temporary flange and insert the flange into the straight pipe. Then, place the straight pipe on the pipe support. (6) Sliding the flange: After sliding the flange onto the flange plates on sides A and B, attach the flange to the flange plates. (7) Pre-welding: When temporarily welding, the bed is protected with anti-spatter agent or glass wool to prevent spatter from adhering to the bed. (8) Tack welding: Tack weld the flanges on sides A and B. (9) Removing the pipe: Remove the flange bolts on sides A and B, loosen the fixing bolt of the flange plate on side A, slide it to side A, and remove the pipe.

[0024] FIG. 5 is a diagram for explaining a pipe manufacturing method using the piping manufacturing jig (L-shaped) of the present invention. The procedure for manufacturing a curved pipe is as follows: (1) Check the pipe dimensions: Check the pipe dimensions L and X. (2) Positioning and fastening of flange plates: Determine the dimension L between the flange surfaces of flange plates 1 and 2A, and fasten flange plate 1 to the bent pipe with M20 bolts. (3) Determine the stopper dimension: Determine the dimension X with the stopper, move the flange plate from 2A to 2B, and then fasten the flange plate 1 and the bent pipe with an M20 bolt. (4) Setting the level (height): Install a pipe support stand at level (height) H as shown in Figure 5. (5) Flange installation and temporary welding: The installation of the pipe, flange installation, and temporary welding are carried out in the same manner as in the case of the straight pipe described above. (6) Removing the pipe: The pipe can be removed while the flange plates 1 and 2 remain in place.

[0025] Figures 6 and 7 are explanatory diagrams of flange plates. Flange plates are designed to facilitate the installation of pipes of various sizes and angles and to allow accurate placement. The details of Figure 6 are as follows: The central section has multiple holes for attaching pipes and flanges, each at an angle of 22.5 degrees or 45 degrees, allowing for multi-angle pipe connections. The circular holes indicate the positions for inserting pipes or flanges of each size, and the hole diameters are also indicated with symbols such as 15A and 20A. The large circular holes on the left and right are clearly marked with the pipe size, with "32A 40A 50A 65A" on the right and "80A" on the left, so it can accommodate a variety of pipe sizes. The thickness of the board (t=16mm) and the location of the hanging holes are also indicated, making it easy to install and handle. The overall dimensions of the plate are shown as "300mm x 250mm", with additional positioning marks at the four corners of the figure.

[0026] The flange plate in Figure 7 shows multiple holes corresponding to specific pipe sizes and angles and is designed to mount pipes and flanges at different sizes and angles for specific piping jobs and installations. Plate size: 300mm long, 250mm wide, plate thickness 16mm (16t). Center Intersection: Multiple angled holes, each at 22.5 degrees or 45 degrees, allow pipes or flanges to be attached from different directions. ·Hole Size: Each hole corresponds to a specific pipe size, indicated in the diagram by a symbol such as "15A 20A", "25A 32A 40A 50A", "65A", "80A 100A", etc. Mounting angle: Angles such as "45 degrees" and "22.5 degrees" are shown in the diagram, and these holes and slots are designed to accommodate connections from different directions. Auxiliary elements: In the upper right corner of the figure there is a "hanging hole" which provides a structure for lifting the plate.

[0027] Figure 8 is an explanatory diagram of a flange, showing the flange shape and size, and showing flanges that correspond to different pipe sizes (15A to 65A). There are two types: flanges with an O-ring (SHA) and flanges without an O-ring (SHB). The presence or absence of an O-ring is a useful specification for selecting a flange. It is also possible to accommodate cases where a different size flange is required.

[0028] Figure 9 is an explanatory diagram of a flange, showing the external dimensions and bolt hole arrangement according to the flange size. Each flange size ranges from 15A to 100A, and the numbers on the drawing indicate the diameter of each flange and the location of the mounting holes. -Flange size: Indicates the flange size, such as "15A", "20A", or "25A". Diameter: Indicates the outer diameter of the flange. For example, 15A is 70mm, and 100A is 210mm. Mounting hole placement: The small circles on the flange circumference indicate the locations of the bolt holes.

[0029] Figure 10 shows the detailed dimensions and structure of the mechanical parts of the present invention, including gears, handles, supports, fixtures, etc. Gear: In the diagram in the center, a gear (GEAR 15T) is used to show the connection relationship with other parts. · Handle: The diagram on the left shows a 300mm diameter handle that works in conjunction with other mechanisms. Supports and fixtures: The dimensions of the mounting points and the positions of the bolt holes of the support and fixtures as seen from the bottom and side are specified. For example, they are fixed with M8 bolts.

[0030] The mechanism uses a gear and rack to change the direction of the lock nut and disengage the gear, making it possible to handle a variety of curved pipes and produce pipes with high precision. Gears are a mechanism that provides rotary motion, primarily used to transmit and control power. Racks provide linear motion, and by meshing with gears, they convert rotary motion into linear motion. This combination makes it possible to transmit power to the required position and direction. Lock nuts are usually used to hold fixed parts in place, but with this mechanism, by changing the orientation of the lock nut, the gear acts in a different direction, allowing the rotation direction and installation method to be changed, making it possible to accommodate complex bent pipe shapes. A gear disengagement mechanism allows the power transmission to be cut off when necessary, allowing free movement in certain positions, allowing it to be stopped in certain sections or switched to manual operation when power is not required. Since curved pipes have curves and bends in various directions, the gears and racks can be used to adapt to the bends, and if necessary, the power transmission can be stopped and the system can be operated manually, allowing for flexible adaptation to the shape and length of the pipe.

[0031] In mechanisms that use gears and racks, the handle (operating tool) serves the following functions: Manual operation of gears and racks In a mechanism where rotating the handle rotates the gear, which in turn moves the rack in a linear fashion, the handle acts as a power source, and the operator can control the device through the gear and rack by turning the handle. - Position and direction adjustment Handles are used to move parts of the equipment to a specific position or change direction. For example, turning a handle rotates a gear and causes a rack to move linearly, allowing parts of the equipment to move forward and backward or up and down. This makes it possible to move in the correct direction even around complex bent pipes. -Operating the clutch function A handle is used to control the engagement and disengagement of gears. If you want to disengage the gears at a specific position, you can turn the handle to activate the clutch mechanism, freeing the gears and allowing the machine to stop or start a different operation. Lock nut adjustment The handle allows you to tighten or loosen the lock nut to lock or unlock the mechanism, making it easy to install or adjust gears and other components, and allowing you to replace or adjust parts as needed. Manual fine-tuning When particularly precise work is required, the handle can be used to make fine manual adjustments, for example by turning the handle in small increments to precisely control the movement of the device and maneuver around complex bends or in tight spaces.

[0032] Figure 11 is an explanatory diagram of the pipe manufacturing method using a piping manufacturing jig (T-type). Flange plates are used to achieve a strong joint. The elements of each part are as follows: ·T-shaped structure Overall, there are two beds extending horizontally and vertically. Flange plate Flange plates are provided at the horizontal and vertical joints. These flange plates are components that firmly secure the pipes together and are connected with bolts. The use of flange plates strengthens the connection between the pipes and accurately maintains the length and direction of the pipes. The role of the jig This invention fixes pipes in precise positions and creates T-shaped joints. It is used in pipe fabrication, allowing pipes to be positioned precisely. The flange plates used provide firm fixation where strength is required. Circular part The circular area shown on the bottom right is a detail of the pipe joint, showing the correct placement and fastening of the connection, ensuring the center section of the T-piece is secure and properly assembled.

[0033] FIG. 12 shows the front surface of the base plate, and FIG. 13 shows the rear surface of the base plate. (1) Base plate surface It has a large circular opening and several small bolt holes, the circular opening being a 21mm diameter hole used for mounting and connecting components. The bolt hole arrangement and slotted hole shape include multiple 24mm slots, which are designed to allow for adjustments and part movement. The thread tap allows for fastening with bolts or screws. (2) Back of base plate The dimensions on the back are 364mm long and 240mm wide, and indicate the overall size and layout of the part, as well as the spacing and location of bolt holes. For example, the width is 120mm, and the dimensions to the location of a specific hole are listed. The material is SUS304 (stainless steel) or high-tensile steel, a stainless steel material that is corrosion-resistant and strong. Base plates are used as the foundation of machines and equipment, and are an important element that supports the connection of each component. They are made of flat bars, and require precision and strength for installation. The placement of bolt holes and slots allows for compatibility and adjustment with other components, and the structure is suitable for installing moving parts.

[0034] Figure 14 shows the structure of the portal leg, with angle irons used at the top of the portal leg for reinforcement. In addition to the angle iron reinforcement, strength is increased by using high-tensile steel members of M12-35 and M12-30. This overcomes the strength issues that arise from the use of gears and racks. In other words, the overall design strength and durability are improved to cope with the loads that arise from the use of gears and racks. [Industrial Applicability]

[0035] The piping fabrication jig according to the present invention can be widely used in fields where piping systems are essential, such as ships, factory equipment, hydraulic systems, and power plant equipment. By using the piping fabrication jig according to the present invention when fabricating large pipes or pipes with complex shapes, work efficiency can be significantly improved compared to conventional methods, and highly accurate piping fabrication becomes possible. In particular, it is expected to be useful in industrial fields where accurate and efficient piping fabrication is required, such as shipbuilding, heavy industry, piping construction, chemical plants, and oil and gas-related facilities.

[0036] Furthermore, this jig can accommodate a variety of flange shapes and sizes, allowing it to flexibly accommodate different piping systems, reducing the workload on-site and contributing to cost reduction. Furthermore, its sliding and rotating functions make it easy to adjust the position of the piping, contributing to improving the safety and working environment of piping fabrication. Therefore, the present invention can be used in a variety of industries related to piping fabrication, and its range of applications is extremely broad. [Explanation of symbols]

[0037] none

Claims

1. The flange plate placed on the bed can be slid along the bed made of flat steel by the rack. The flange plate can be freely rotated by rotating the gear, and the position of the flange plate can be freely adjusted by a lifting mechanism that can move it up and down. Furthermore, the piping fabrication jig is characterized in that the gear can be switched between an engaged state with respect to the rack and a disengaged state by rotating the lock nut by a predetermined angle and moving the gear in the axial direction by a predetermined distance in conjunction with the lock nut, and after rotating the flange plate in the disengaged state of the gear, the flange plate can be rotated by changing the rotation angle of the flange plate and by re-engaging the gear.

2. 2. The piping fabrication jig according to claim 1, further comprising a mechanism for disengaging the gear from the rack by rotating the lock nut and axially moving the gear in conjunction with the lock nut, using the gear and the rack.

3. 2. The piping fabrication jig according to claim 1, characterized in that bolt holes in the form of elongated or circular holes arranged at 22.5 degrees or 45 degrees from a predetermined reference position provided in the flange plate are provided with additional holes for lifting fixtures, making it possible to attach square flanges or other specially shaped flanges, and thus enabling the attachment of a variety of flange shapes.

4. The piping fabrication jig according to any one of claims 1 to 3, The flange plate is capable of mounting a variety of flanges ranging from 15A to 125A for marine piping, and is capable of manufacturing piping up to 5.5 meters in length.

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