System and Method for Orientated Tube Bending

Abstract

Herein a description of a processing system for bending tube from a feed position. The device is such that the rotation of the bending components of the machine rotates regardless of the rotation of the workpiece affording 2 degrees of rotational freedom. The bending components allow the bend in a tube to change with respect to the bending plane without rotating the tube. The bending components allow the orientation of the bending device to rotate without having to move the entire machine. The device may also be rotated independent of the workpiece, and, the workpiece may be rotated independent of the device.

Description

BACKGROUND OF THE INVENTION

[0001] Tubes are used in multiple industries with varying functions and applications. Tubes are found in industries such as oil and gas exploration, shipbuilding, agriculture, various geological industries, automotive, aerospace and construction.

[0002] The novel rotational bending die for tube processing systems described herein are more cost effective than purchasing two or more separate machines to bend tube in one general orientation or another. Further, maintenance expenses are lower for the rotational bending die for tube processing systems compared to the expenses required to maintain two separate machines.

[0003] Most tubing benders are horizontal, meaning that the tubing is bent along a horizontal plane parallel to the floor. Depending on the direction, a bend can be described as a leftward or a rightward bend. Furthermore, there exists bending machinery that bends vertically. These machines usually bend in a fashion that is up or down as opposed to left or right. Both horizontal and vertical machines have their benefits and drawbacks. Horizontal machines are good for changing tooling that requires heavy machinery to handle the components due to their significant mass. When dies and other tooling components of the machine are very heavy, lifting them off the machine with cranes and hoists and other overhead lifting equipment is generally the easiest and safest solution, which is easier on horizontal machines

[0004] The drawback to horizontal bending orientation machines is observed when shop space and obstructions are considered. If a bent part has 5 feet of straight tube before a 90-degree bend, and it is rotated 90 degrees before the next bend, the end of the tube will be 5 feet below the bending centerline in the machine. If the machine's bending centerline is 3 feet from the ground, the tube being bent will hit the ground when it is rotated either to the left or to the right, depending on the orientation of the machine.

[0005] Fabricators remove this limitation by purchasing mirroring bending machines where one bends to the right, and the other to the left. Additional floor space and maintenance of both machines is required. Another drawback is that the arc formed by the tubing being bent covers a large area with horizontal machines. This area must be kept clear and displaces other valuable operations in a shop space. A common solution for bends of this type is to use a machine that bends vertically. This allows the same part to be made with rotation to the right or left without floor contact. While bending up, most parts will swing into drastically less valuable shop space, increasing available space as well as operator safety but introduces another machine that occupies floor space and requires maintenance.

[0006] The present disclosure invention conveys a processing system for bending tube in any direction. The device described herein has features that allow the entire bending mechanism of the device to rotate independent of the machine it is housed on. The rotation of the device may be independent of the workpiece rotation. Additionally, design variations exist where the workpiece may be rotated independent of the device. This allows the user to adapt to the requirements of the specifications of the workpiece specifications.

[0007] The workpiece bending die is driven by a motor. The motor is affixed to hardware that allows the die and motor assembly to rotate. Additionally, the rotation of the motor and die assembly rotates about the center line of the workpiece being bent. This allows the bends in the workpiece to stay true whereby the circular cross section of the tube is maintained without deformity of the tube profile. The rotation of the die and motor assembly includes clamps affixed to the die.SUMMARY OF THE INVENTION

[0008] The work presented in the present disclosure is directed to tube bending wherein the tube may be bent at any angle. The tube bending mechanism includes a rotating bending die head that rotates independently of the mount it is affixed to. The tube bending mechanism rotates independent of the tube being processed. The rotating die is configured to bend the tube into any angle. The tube may be translated or rotated independent of the position of the rotating die. The axis of rotation of the bending die is perpendicular to the axis of rotation of the die rotation about the tube's center line. The bending die mount is rotationally driven about the central axis of the tube to bend the tube at any angle.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIGS. 1-3 depict the device from a frontal view, wherein the device is set at zero angle in FIG. 1, then rotated 45 degrees in FIG. 2, then in FIG. 3, the device is rotated 90 degrees from the position shown in FIG. 1.

[0010] FIGS. 4 and 5 depict a side view of the device wherein FIG. 4 depicts the bending die in a vertical position whereas FIG. 5 shows the same side view where the bending die is rotated 45 degrees.

[0011] FIGS. 6 and 7 depict the device from a top view. FIG. 6 depicts the bending die rotated 90 degrees from the vertical position wherein FIG. 7 depicts the bending die in a vertical position.

[0012] FIGS. 8-10 depict the device from a three-quarter view wherein the bending die starts at the vertical position in FIG. 8; then the die is rotated 45 degrees in FIG. 9, then in FIG. 10 the die is rotated 90 degrees from the vertical position shown in FIG. 8.DETAILED DESCRIPTION OF THE INVENTION

[0013] With reference to the figures, the rotational bending die for tube processing systems will now be described. The rotational bending die for tube processing systems discussed herein function to bend tubes in any orientation.

[0014] The reader will appreciate from the figures and description below that the presently disclosed rotational bending die for tube processing systems address many of the shortcomings of conventional approaches bending tubes with a device that has a fixed bending die orientation. For example, the novel rotational bending die for tube processing systems described herein remove the need for operators to use two separate devices to bend a tube with specific orientation. The ability of the operator to bend tube at any rotational orientation with a single system is beneficial for many reasons.

[0015] Industries involved in tube bending no longer have to choose a tube bender that are limited to a left-handed or right-handed orientation. The disclosed invention allows for either within the same machine without sacrifice to quality or workflow.

[0016] The workpiece bending die is driven by a motor. The motor is affixed to hardware that allows the die and motor assembly to rotate. The rotation of the motor and die is about the center line of the workpiece being bent. This allows the bends in the workpiece to stay true whereby the circular cross section of the tube is maintained without deformity of the tube profile. The rotational axis is set to be about the centerline of the tube being bent. The rotation of the die and motor assembly includes clamps affixed to the die.

[0017] The rotating die mechanism's rotation may be driven by any means. In one embodiment, by semicircular gear teeth affixed to a worm drive. Another embodiment is such wherein the device is driven by a direct drive motor to drive the rotating mechanism. Further embodiments encompass a manual input such as a hand cranking system.

[0018] The disclosed device may be stand alone or accompanied with a larger work flow assembly that is either automated, semi-automated or manually operated, with or without motor-driven power.

[0019] One important improvement over conventional approaches to bend tube is that the novel tube processing systems described in this document increase accuracy and precision. With the presently described novel tube processing systems, an operator does not need to align a tube multiple times on separate machines, which is prone to inaccuracy. By utilizing a single machine to bend a tube in any orientation, the bend may be aligned more accurately.

[0020] Processing speed and convenience also improve when utilizing the novel rotational bending die for the tube systems herein to bend a tube in any orientation with a single machine. Processing time is saved because an operator does not need to set up multiple machines, transfer a tube from one machine to another, and align the tube as accurately as possible in each machine. In addition to improved processing speed, the ability to bend a tube in any orientation with a single machine is more convenient for the operator than having to use multiple machines.

[0021] The footprint of the entire machine housing the rotational die is another benefit of the novel rotational bending die for tube systems described below. With tube bending from any orientation provided by a single machine, only one support system for long tubes is needed rather than two separate support systems for separate machines. It is easier to find space in a machine shop to house a single machine with one support system (wherein these support systems oft-times are as much as 20-feet) than it is to house two machines each having support systems of this length.

[0022] Tube is bent to defined parameters by the rotational bending die described heretofore. The tube may be any of any currently known material or one yet to be developed wherein the only requirement is that the material be malleable. The reader will appreciate that a variety of tube types exist, in profile, wall thickness and material, that could be manipulated on the disclosed device.

[0023] Variance of the length, outer diameter (OD), inner diameter (ID), differences between the OD and ID of the tube (wall thickness), inherent material of the tube (copper, iron, alloy, composite) are heretofore referred to as tube specifications. These tube specifications may be varied as needed for any given application. In some examples, the tube is larger relative to the other components than depicted in the figures. In other examples, the tube is smaller relative to the other components than depicted in the figures. Further, the reader should understand that the tube and the other components may all be larger or smaller than described herein while maintaining their relative proportions. It is also noted that the geometry of the die relative to the size of the tube specifications may scale depending on the specifics of the application of the rotating tube bending die mechanism and may or may not be depicted to scale in the drawings.

[0024] The device may be mounted to a workbench, stand-alone cabinet, work truck or any other means of support. The device may be stand alone, driven by manual input. The device may be part of a larger assembly line of tube processing either powered by motor or powered by hand.

[0025] The device is designed such that the bending die may rotate around the workpiece while the workpiece may rotate simultaneously independent of the rotating bending die. This free rotation of either part of the device affords the device 2 degrees of rotational freedom about the coaxial line of the tube and the bending die.

[0026] FIG. 1 illustrates a frontal view of the rotating bender die (100) with die clamp (103) in a horizontal position. The bending die (100) is rotated perpendicular to the feed direction of the tube being bent (101). The rotation of the die is driven by semicircular gears (104). The means to drive the rotation of the bending die about the center line axis of the workflow piece (106) of the bending die may be a direct drive system, a belt driven system or any other mechanical means to rotate the die into the sought-after position. In FIG. 1, the rotating bending die and the mechanical system is shown mounted to a free-standing cabinet (105). The section of the pipe that is fed is held in position by an ordinary shop stand. An electric motor to drive the rotating bending die is shown at (102)

[0027] FIG. 2 is a frontal view of the device with the housing cabinet (109) rotated 45 degrees. The worm gear drive is seen at (106) driving the rotation of the housing unit (109).

[0028] FIG. 3 is a frontal view where the bending components are rotated 90 degrees from the vertical position. The housing unit (109) is parallel to cabinet (105). The tube section being bent is seen at (101).

[0029] FIG. 4 is a side view of the device such that the housing unit (109) is rotated 45 degrees from the horizontal position. The housing unit (109) and the components that comprise it (100-103) are depicted. The device is shown to sit on a cabinet (105).

[0030] FIG. 5 shows a side view of the device with all of the features shown.

[0031] FIG. 6 is a top view with the housing unit (109) and the bending components it contains rotated 90 degrees, rendering it parallel to the work bench as seen in FIGS. 8-9.

[0032] FIG. 7 shows the device from a top view wherein the bending die is in the horizontal position. The motor to drive the rotation of the rotating die is seen at (102). The feed end of the tube is clamped at (108). The cabinet holding the device is seen at (105). The semicircular drive components that drive the rotation of housing unit (109) are seen at (104). In this FIG. (105) is perpendicular to (109).

[0033] FIG. 8 shows the device from a side view wherein the bending die is in the horizontal position. The bending die (100) and clamp (103) is shown. The device sits on a cabinet (105) intended to hold the device in place. The device may be mounted to a workbench or other suitable substrate. The device can be mounted to a larger assembly of tube processing systems. The clamp to hold the tube to the die is seen at (103). An unremarkable electric motor drives the rotation of the die (100) and affixing clamp (103). The workflow piece is held in place by clamp (108) and is supported by (107). The rotation of the die about the centerline of the tube is driven by (106) wherein a hand crank, electric motor, or other means of rotational power may be connected. Rotating (106) will rotate the entire die assembly and motor (100 and 102, respectively). The tube may or may not rotate with the die rotation about the tube's centerline.

[0034] FIG. 9 is a side view of the device where the bending die (100), die clamp (103), motor (102), are affixed to housing unit (109) wherein the housing unit is rotated 45 degrees. The device is mounted to cabinet (105). The workflow is supported by (107).

[0035] FIG. 10 is a side view wherein the housing unit (109) and its components are rotated 90 degrees from the vertical, therefore parallel to the workbench cabinet (105). The bent pipe is seen at (101).

[0036] FIG. 11 illustrates the two degrees of freedom, marked “A” and “B”, about the coaxial line whose point may been seen at the center of the “x”.

Claims

1. A tube processing system for bending a tube fed from a feed position, wherein the bending system includes:A bending die that is rotationally driven to bend the tube (wherein this defines the plane perpendicular to the axis of rotation to be the “bend plane”; anda clamp configured to secure the tube to the bending die at precise locations along the tube; and a pressure die to oppose bending on the side of the die opposite the clamp; anda means to rotate all or part of the bending die system to adjust the angle of the bending plane relative to the environment.

2. The tube processing system described in claim 1, with a means to have the workpiece rotate relative to the rest of the machine creating two concentric, independent degrees of rotational freedom in the system wherein the bending die may or may not be clamped while the workpiece may or may not be clamped.

3. The tube processing system described in claim 2, where both workpiece and bending die are free to rotate simultaneously by either the same drive source or independent sources.

4. The tube processing system described in claim 1, where a non-rotating clamp is used to secure the workpiece being processed from rotating about the central axis of the workpiece to prevent movement of the workpiece when the clamp is not closed or gripping the workpiece, locking one of the degrees of rotational freedom.

5. The tube processing system described in claim 1 where multiple clamps (from claim 1 and claim 4) allow alternation of clamping cycles with rotation to achieve unlimited rotation of the workpiece in small rotational steps with any single-cycle rotation capacity limit of the system alternating the rotational degrees of freedom at will.

6. The tube processing system described in claim 1, where the system or a portion of the system is mounted to a device suitable to rotate the die bending mechanism about the center line of the workpiece that facilitate the rotation of the bending plane while maintaining the workpiece to be bent on a constant axis with feed system.

7. The tube processing system described in claim 1, with gear, chain, toothed belt, friction belt, or other drive features to facilitate the rotation of the bending mechanism integrated into or mounted to the device in claim 6.

8. The tube processing system described in claim 1, with a worm-type gear driving the gear teeth or other driving features of claim 7.

9. The tube processing system described in claim 1, with a powered drive system to manually or automatically power the rotation of the bending mechanism in claim 7 to achieve rotation of the bend plane within the system in coordination with other machine system's movement.

10. The tube processing system in claim 1, where the bending plane can achieve bend plane orientation of up to at least 0 degrees from horizontal (bending “right”) and 90 degrees from horizontal (bending “up”).

11. The tube processing system in claim 1, where the bending plane can achieve bend plane orientation of up to at least 0 degrees from horizontal (bending “right”) and 180 degrees from horizontal (bending “left”).

12. The tube processing system in claim 1, where the driving mechanism in claim 6 rides on friction-reducing device(s) (such as bearings, bushings, magnet(s), fluid film, or other) that aid in the movement and control the rotation of the bend plane.

13. The tube processing system in claim 1, where there is a mechanical means of locking the bend plane angle, such as bolts, pins, clamps, magnetic locks, hook-and-loop, thermal expansion locking, or other means.

14. The tube processing system in claim 1, where the rotation system drive in claim 7 includes anti-backlash (or backlash compensation) devices such as split-nuts, split gears, variable pitch or pitch diameter gears or drivers, adjustable gear mesh or engagement, or other means.

15. The tube processing system in claim 1, where the system uses a mandrel or mandrel(s).

16. The tube processing system in claim 1, where the system uses a translating pressure die to support the tube.

17. The tube processing system in claim 1, where the system uses threaded or other adjustments for position of the friction reducing elements in claim 12 to reduce the backlash of the system.

18. The tube processing system in claim 1, where the system uses a power drive system such as motor with gear or screw components to convert to linear motion, or other common means of linear actuator like a hydraulic, pneumatic, or other type of actuator to move the pressure die in claim 16 during tube bending operations.

19. The tube processing system in claim 1, wherein the system does not use a cylindrical feature co-axial to the member being bent as in claim 5, and instead uses another means to secure the rotational position of the system or sub-system to achieve control of bend plane rotation, such as multiple patterns of fastener(s), including, but not limited to: bolts, pins, keys and the like, which can be arranged in various holes that line up between the bending die portion of the system and the frame-like feature of the machine / system, or with said fastener(s) instead installed in straight or annular slots, with or without a method for locking bend plane rotation as described in claim 13.

20. The tube processing system in claim 1, wherein the system does not use a cylindrical feature co-axial to the member being bent as in claim 5, and instead uses contact surfaces or points between the two moving sections (the die bending sub system and the frame-like system) to establish multiple fixed angular positions for the bend plane angle, with or without a method for locking bend plane rotation as described in claim 13.

21. The tube processing system in claim 1, wherein the system does not use a cylindrical feature co-axial to the member being bent as in claim 6, and instead uses the member being bent as the support feature for the bending sub-system, with or without a method for locking bend plane rotation as described in claim 13.

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