Method and system for forming a foundation pile section

Abstract

Method and system for forming a foundation pile section with a desired diameter and circumference, wherein the section has a circular cross section perpendicular to a longitudinal axis of said section, wherein a plate having a width direction and a length direction perpendicular to the width direction, is rolled in said length direction into a cylindrical or frusto-conical shape, such that opposite ends of said plate are brought in an adjacent position, wherein during and / or directly after rolling a circumference and / or diameter cq radius of the rolled plate are assessed, whereby an edge portion of the plate at at least one of said adjacent opposite ends is removed, where after said then adjacent opposite ends are brought together and welded together

Description

[0001] Title: Method and system for forming a foundation pile section

[0002] The invention relates to a method for forming a foundation pile section. The invention further relates to a system for forming a foundation pile section.

[0003] Foundation piles such as monopiles are known to be made of steel sections which have a tubular, cylindrical shape and are mounted on top of the other along a longitudinal axis. An upper end of such foundation pile can be frusto conical, for example for forming a slip joint with a transition piece, a tower of a wind generator, or a platform, or combinations thereof or straight, ending in a flange to connect a transition piece, a tower of a wind generator, or a platform, or combinations thereof. Each section is formed from a plate which is rolled into said tubular cylindrical or frusto conical shape, wherein longitudinally opposing ends are forced in abutment with each other and are welded together.

[0004] The tubular sections can be made of steel plate having a thickness of centimeters, for example 3 to 4 centimeters or more, and can have a diameter of up to ten meters or more. Nevertheless these sections have to be made with a predefined diameter or circumference within relatively small tolerances, which is in the order of millimeters, for example less than 4 millimeter in diameter. This has been proven to be very difficult and cumbersome.

[0005] In order to meet the necessary tolerances metal plates are cut to a length, calculated on the bases of the set diameter or circumference of the section, according to the equation length L is n times the diameter D (L= n D). It has however been found that even when the length of the plate to be rolled is accurately calculated and the plate is cut accordingly, the diameter of the resulting section often does not comply with the predefined diameter or circumference due to the rolling process affecting the pre-cut length. Methods for adjusting diameters of cylindrical bodies known in the art can be practical for relatively thin walled, small diameter bodies like pipes, boilers and the like, but are not suitable for forming thick walled plates into cylinders for foundation piles, which have a very large diameter and need to have cross sections with tolerances in the millimeter range.

[0006] For example in FR1102859 it is described for thin walled boilers to roll a thin plate into a cylinder shape, wherein the longitudinal ends of an initially flat plate are brought into an overlapping position, in which position they are fixed by welding a clamp to the inside surfaces of both ends. Then the overlapping portion of at least one of said ends is removed, such that a proper abutment is obtained of the resulting ends, which are then welded together.

[0007] DE 102019007606 discloses a press system for forming tubes of metal plate, wherein the plate is first pressed into a U-shape, wherein the inner contour is measured, whereafter the plate is pressed further into a tubular shape, with ends meeting. Then the meeting ends are welded together, after which the tubular shape is pressed from the inside into the desired cross section by stretching the plate.

[0008] JP2013121608 discloses a system and method for bending a flat plate into a cylindrical pipe, wherein the plate is first bent into a C-shape and then forced further, by a four roll press, into the desired cross section, wherein a distance between opposite ends of the plate is measured using a camera system. The plate is forced further into the cylindrical shape until a desired width is achieved for welding the ends together.

[0009] There is a need for an alternative method and / or system for forming foundation pile sections. An aim of the disclosure is to provide for such method and / or system. An aim of the disclosure is to provide for a method and / or system for easily and accurately forming foundation pile sections from metal plate. An aim of the disclosure is to provide for a method and / or apparatus for accurately forming foundation pile sections from metal plate, accurately with a diameter and / or circumference within apphcable tolerances.

[0010] At least one of these and other aims are at least partly obtained with a method and / or system according to the disclosure, especially as defined in the appending claims.

[0011] In an aspect a method according to the disclosure is for forming a foundation pile section with a desired diameter and circumference, wherein the section has a circular cross section perpendicular to a longitudinal axis of said section. A plate having a width direction and a length direction perpendicular to the width direction, is rolled in said length direction into a cylindrical or frusto-conical shape, such that opposite ends of said plate are brought in an adjacent position. According to a method of the disclosure during and / or directly after rolling a circumference and / or diameter of the rolled plate are assessed, whereby an edge portion of the plate at at least one of said adjacent opposite ends is removed in order to achieve the required circumference after rolling and before applying the final longitudinal weld. The then adjacent opposite ends of the plate are then brought together and are welded together.

[0012] By removing an edge portion of the plate at at least one of opposing longitudinal ends of the plate during or after rolling of the plate into a tubular shape, wherein the length of the edge portion to be removed, seen in the circumferential direction of the rolled plate, is defined based on an assessed diameter or circumference, which is to be understood as circumferential length of the rolled plate, the foundation pile section can be more accurately be made to specifications, in an easy manner.

[0013] In alternative embodiments of a method of the disclosure for forming a foundation pile section with a desired diameter and circumference, wherein the section has a circular cross section perpendicular to a longitudinal axis of said section, a plate having a width direction and a length direction perpendicular to the width direction is rolled in said length direction into a cylindrical or frusto-conical shape, such that opposite ends of said plate are brought in an adjacent position. In such alternative embodiments of a method of the disclosure a circumference and / or diameter of the rolled plate are assessed and a gap is kept between opposite longitudinal ends of the plate. In such embodiments then the distance between said opposite ends is measured and a new portion, also referred to as new edge portion, is fitted filling the gap.

[0014] It shall be clear that where diameter is used this should be understood as including radius, unless specifically defined otherwise. Circumference should be understood, when referring to a dimension, as meaning a circumferential length.

[0015] In a method of the disclosure in embodiments adjacent opposite ends are forced against each other during assessment of the circumference and / or diameter cq radius of the rolled plate prior to said removing of the edge portion. In such embodiments the diameter cq radius or circumference, assessed with the opposing longitudinal ends forced against each other is compared with a desired diameter cq radius or desired circumference, wherein the length of the edge portion to be removed seen in said circumferential direction is defined by the difference between the relevant assessed dimension and the corresponding desired dimension.

[0016] Alternatively the relevant dimension, such as diameter cq radius or circumference is assessed while said opposing longitudinal ends of the rolled plate are held spaced apart over a known and / or measured distance. In such embodiments the assessed dimension is again compared to a desired dimension. In embodiments in defining the length of the edge portion to be removed is calculated based on said comparison and the known distance between the opposing ends. In alternative embodiments a new edge portion is defined based on said distance between said opposing longitudinal ends.

[0017] In very practical embodiments of a method of the disclosure the diameter and / or circumference are assessed by measuring the circumference of the plate between the said opposing ends at at least one cross section and the width of a gap between said opposing ends, and calculating the difference between at least one of the diameter or the circumference as is and the diameter or circumference as desired.

[0018] In very practical alternative embodiments of a method of the disclosure the diameter and / or circumference are assessed by, during and / or after rolling, measuring the diameter or radius of the plate at at least one cross section and the width of a gap between said opposing ends, and calculating the difference between at least one of the diameter or the circumference as is and the diameter or circumference as desired.

[0019] As discussed, in embodiments during said assessment the width of the gap can be zero while making the measurement. Measuring the diameter or radius can for example be done electronically or manually, for example at an outer or inner surface of the rolled plate.

[0020] In a method of the disclosure preferably the plate is rolled using a roller press, more preferably a roller press connected to or comprising a computer system. In the computer system preferably data is stored concerning at least one of a desired diameter of a section to be formed and a desired circumference of a section to be formed. A desired circumference should be understood as meaning a peripheral length measured along a surface of the section to be formed. A desired diameter should be understood as including but not limited to a desired radius. In such method preferably an assessed diameter and / or circumference is compared with said set, desired value for the diameter and / or circumference, wherein based on said comparison a length of said edge portion in the length direction of the plate is defined. In embodiments then said edge portion is then removed based on said defined length of the edge portion, whereas in alternative embodiments a new edge portion is added based on said defined length.

[0021] In a method of the disclosure preferably a plate is used having an excess length for the section to be formed. In other words, preferably the method is started with a plate of which the length of the plate, measured in said length direction along a surface of the plate between said opposite ends, prior to said rolling, is larger than a circumferential length of the plate after said welding. Thus it is ensured that always an edge portion can be removed after rolling. In the alternative embodiments of a method of the disclosure, in which a new edge portion is added, preferably the initial length of the plate is shorter than the final circumferential length of the section to be formed.

[0022] A plate for use in a method or system of the disclosure can be a single plate or a series of interconnected, especially welded plate sections.

[0023] In embodiments a roller press is used for rolling the plate into said cylindrical shape, wherein at least one of measuring the diameter or radius and / or circumference, removing of the at least one edge portion and welding, such as welding said opposing ends together or welding the new edge portion between opposite ends is performed while the plate is in said roller press. Preferably at least two of measuring the diameter or radius and / or circumference, removing of the at least one edge portion and welding is performed while the plate is in said roller press, more preferably all three.

[0024] In a method according to the disclosure preferably said diameter or radius is measured using a contact free measurement system or method. In advantageous embodiments said diameter or radius is measured using a laser based system measuring relative speed of a surface of the plate passing a measurement instrument. In a system of the disclosure preferably the system is designed for contact free measurement of speed and / or length of a surface of a plate of metal being rolled by the roller press passing by said measurement system and calculating at least one of a circumferential length of the plate during rolling and a diameter of a cylindrical or truncated conical tubular body being formed from said plate and controlling the roller press during rolling based at least on said calculations. In especially advantageous embodiments the contact free measurement system is a laser based measurement system, preferably a laser surface velocimeter (LSV). The laser based measurement system can in embodiments be configured to during use emit at least one laser beam or a combination of laser beams towards the surface of the tubular body, the laser beam or combination of laser beams having a center line radially to a tubular body being formed in said roller press.

[0025] The disclosure further relates to a roller press system for pressing a plate into a cylindrical or frusto conical shape. In an aspect of the disclosure the roller press system comprises at least a roller press and a computer system, part of or connected to the roller press. Furthermore at least one measurement system is provided for measuring at least one of a diameter, radius and circumference of a plate while being or after having been rolled in said roller press, and feeding data concerning said diameter, radius and / or circumference into the computer system. The measuring system is further designed for measuring a distance between two opposing longitudinal ends of the plate, and feeding data concerning said distance into the computer system.

[0026] In the computer system a desired diameter, a desired radius and / or a desired circumference of a cylinder to be rolled from said plate are stored. The computer system is preferably construed for assessing an as is diameter, radius and / or circumference of a cylinder rolled from the plate as is, comparing said as is diameter, radius or circumference with the desired diameter, radius or circumference as stored in said computer system and calculating, based on said comparison, a length of an edge portion either to be removed from the plate when having been rolled towards the cylindrical or frusto conical shape or a length of a new edge portion to be welded between said opposite ends when having been rolled towards the cylindrical or frusto conical shape. Preferably in a system of the disclosure the computer system is further programmed to operate a device for removing said at least one edge portion. Such device is for example but not limited to a milling device such as but not limited to a CNC-milling device.

[0027] In embodiments the device for removing said at least one edge portion can comprise two milling devices or saws or the like, placed in a side by side relation, such that simultaneously an edge portion can be removed from both opposite ends, wherein preferably a distance between said milling devices can be set.

[0028] Removing an edge portion and especially removing an edge portion at both longitudinal ends can have the advantage that the or each opposite end is provided with a desired straight configuration, especially parallel straight configuration, making welding even better possible after bringing said opposite ends together.

[0029] In a system of the disclosure preferably the computer system is furthermore programmed to operate the roller press after removal of said at least one edge portion, for forcing opposite ends of the remaining plate against each other. Thus the plate can efficiently be brought to the desired diameter / radius and circumference, as set in the computer system.

[0030] In embodiments of a system of the disclosure the computer system is further programmed to operate a welding system, for welding said opposite ends of the remaining plate together, at least by tack welding or for welding a new edge portion in between opposite ends of the plate after rolling.

[0031] The invention will be further elucidated on the basis of exemplary embodiments which are represented in the drawings. The exemplary embodiments are given by way of non-limitative illustration of the invention. In the drawings schematically shows:

[0032] Fig. 1 in top view schematically a plate for forming a foundation pile section, in flat configuration; Fig. 2 in side view a plate of fig. 1, in a roller press of a roller press system of the disclosure, during forming of said foundation pile section, wherein the plate is in a first, intermediate, rolled position, with abutting opposite ends;

[0033] Fig 2A an alternative set up for a contact free measurement system;

[0034] Fig. 3 a plate according to fig. 2, during assessment of a diameter of the plate in said first, intermediate, rolled position;

[0035] Fig. 4 a plate according to fig. 2 during removal of an edge portion;

[0036] Fig. 5 the plate according to fig. 4, after removal of said edge portion and after rolling the plate further to an end position;

[0037] Fig. 6 in side view a plate of fig. 1, in a roller press of a roller press system of the disclosure, during forming of said foundation pile section, wherein the plate is in a first, intermediate, rolled position, with opposite ends spaced apart;

[0038] Fig. 7 a plate according to fig. 6, during assessment of a diameter of the plate in said first, intermediate, rolled position;

[0039] Fig. 8 the plate according to fig. 7, during removal of said edge portion;

[0040] Fig. 9 the plate of fig. 7 and 8 after rolling the plate further to an end position;

[0041] Fig. 10 the plate of fig. 4 or 8, during welding, especially tack welding, of the opposite ends of the plate;

[0042] Fig. 11 an alternative embodiment of a plate, for forming a truncated conical section, in top view;

[0043] Fig. 12 a plate of fig. 11, in a roller press of a roller press system of the disclosure, during forming of a truncated conical foundation pile section, wherein the plate is in a first, intermediate, rolled position, with abutting opposite ends; Fig. 13 in side view a plate of fig. 1, in a roller press of a roller press system of the disclosure, during forming of said foundation pile section, wherein the plate is in a first, intermediate, rolled position, with spaced apart opposite ends;

[0044] Fig. 14 in side view the plate of fig. 13 in the roller press system, with a new edge portion positioned between said opposite ends; and

[0045] Fig. 15 inside view a plate in a roller press system with an alternative measurement system, wherein the measurement system is a contact free measurement system, such as but not limited to a laser surface velocimeter (LSV).

[0046] In this description embodiments of the invention will be described with reference to the drawings by way of example only. These embodiments should by no means be understood as limiting the scope of the disclosure. At least all combinations of aspects, elements and features of the embodiments shown and discussed are also considered to have been disclosed herein. In this description the same or similar elements and features will be referred to by the same or similar reference signs. The drawings are not to scale, and can show exaggerations in order to more clearly show features of the claimed invention.

[0047] In this description wording like substantially and generally should be understood as meaning that relatively small deviations from the feature or value they refer to are also considered to be covered, for example deviations of 20% or less, such as 15% or less or 10% or less, unless specified differently.

[0048] In this description embodiments of a section of a foundation pile are disclosed, the foundation pile being provided for supporting for example a platform and / or a wind turbine generator (WTG) supported on the foundation pile, directly or indirectly. When performing a method of the disclosure and / or using a system, or parts thereof, according to the disclosure any such platform, WTG or the hke, with any transition piece if provided, is preferably removed from the foundation pile beforehand.

[0049] A foundation pile section of the disclosure has a diameter of several meters to more than ten meters, for example up to or above fifteen meters at its lower end, and can have a wall thickness, if made of metal, of centimeters, for example more than 2 centimeters, such as more than 4 centimeters, such as for example 8 to 10 centimeters or more. These sizes are only given by way of example and should not be considered to limit the disclosure. For forming a foundation pile, also referred to a as monopile, several cylindrical foundation pile sections are mounted on top of each other. Cylindrical should in this disclosure be understood as meaning having a longitudinal axis, wherein each cross section perpendicular to the longitudinal axis is circular. The sections can have the same diameter at a top end and the bottom end or different diameters, such as in a truncated conical section.

[0050] In this description bringing opposite ends of a plate to adjacent or abutment position should be understood as bringing said ends in a position relative to each other that they both lie substantially on an imaginary circle defined by said rolled plate, wherein these opposite ends are not in a side by side relation. In other words, in a method according to the disclosure the opposite ends preferably do not pass each other. In other words the inside surface of one of said opposite ends is not brought alongside an outside surface of the other opposite end.

[0051] Fig. 1 shows in top view a plate 1 for forming a tubular section 2 (e.g. fig. 10) of a foundation pile. The plate 1 has a length L in a length direction 3, a width W in a width direction 4 and a thickness T thickness direction 5, in fig. 1 perpendicular to the plane of drawing. The plate 1 is made of metal, preferably steel, as commonly used for monopiles. By way of example only, not limiting the scope of the disclosure, a plate 1 can for example have a length Li before rolling of over 10 meters, such as for example at least 20 meters, which length Li before rolling can also be referred to as starting length Li or initial length Li, which should be understood as a length Li, prior to removing of at least one edge portion 6 or before adding a new edge portion as will be explained. The plate 1 for example has a width W of over 3 meters, such as at least 4 meters, and a thickness T of at least 10 mm, for example 20 mm or more, such as for example 40 mm or more. The length direction 3, width direction 4 and thickness direction 5 preferably extend perpendicular to each other.

[0052] The plate 1 as shown in fig. 1 prior to rolling is preferably flat and has opposite initial ends, which can also be referred to as a first end or first initial end 7 and a second, longitudinally opposing end, which can also be referred to as a second initial end 8. As will be explained, in embodiments of a method according to the disclosure at least at one of the opposing ends 7, 8 of the plate 1 an edge portion 6 will be removed, thus forming a new relevant first or second end 7 A, 8A, which can also be referred to as final first end 7A and / or final second end 8A. It will be clear that if only at one end of the plate an edge portion 6 is removed, one of the initial ends 7, 8 will also be the relevant final end 7 A, 8A. When at both ends an edge portion 6 is removed, both opposite ends will be the new or final opposite ends 7 A, 8A. In fig. 1 as an indication an edge portion 6 is indicated as delimited by the striped line indicating a new end 8A. The length Le of the edge portion to be removed will however only be defined during or after an initial rolling step, as will be discussed.

[0053] By removing at least one edge portion 6 the length Li of the plate 1 is reduced to a final length L2. Said final length L2 is to be measured along a surface of the plate 1, which can be the inner surface 9 or the outer surface 10.

[0054] In alternative embodiments in stead of or after removing an edge portion 6 a new edge portion 30 is added to the plate, after rolling of the plate 1, between then adjacent opposite ends 7, 8, for filling a gap between said opposite ends 7, 8.

[0055] It has been found that during rolling of the plate 1 the dimensions of the plate 1 will change uncontrollably. Any one of the length L, the width W and the thickness T may change, whereas for different plates 1 the changes may be different, both in directions and dimensions, even when starting from similarly sized plates of the same material. Thus even if according to the prior art a series of plates 1 is cut to a predefined length, based on L= n*D, wherein D is the desired diameter and L is the initial length of the plate, foundation pile sections formed from such plates will have different diameters, which is undesirable.

[0056] With embodiments of a method according to the disclosure, wherein the length of the plate 1 is reduced only after it has been rolled into a tubular shape close to the desired shape and dimensions, correction is obtained for any such uncontrolled change in the length and thus circumferential length of the plate, ensuring in a practical and easy manner that tubular foundation pile sections made will have the same diameter. Similarly by rolling a plate into and initial shape having the right cross section dimensions, such as diameter, radius and / or circumferential length, but with a gap between said opposite ends, measuring a distance between the opposing ends and filling the gap with a new edge portion made to fit said gap.

[0057] In relation to fig. 2 - 10 and 12 roller press systems and plates are shown used in a method in which at least one edge portion of the plate is removed after rolling, whereas in relation to fig. 13 and 14 a roller press system and plate are shown in a method in which an edge portion is added after rolling.

[0058] A method according to the disclosure for forming cylindrical or truncated-conical tubular bodies, having a hollow, tubular configuration, by rolling a plate of metal into said tubular configuration using a roller press, wherein the roller press is controlled by a control device, can comprise the steps of during rolling of the plate into the tubular form the plate moving the plate through the roller press, wherein during said rolling a contact free measurement system is used for measuring at least speed of movement of the plate through the roller press, wherein data obtained from said measurement is used for controlling the roller press. The data can at least be used for controlling the roller press at least by setting at least one roll of the roller press relative to at least one other roll of said roller press, for example for assessing a diameter of a plate at a given moment during rolling, preferably at least once prior to welding. Said data is preferably at least obtained when the plate is rolled such that two opposite ends of the plate are close together, more preferably at least when said ends are in abutment, contacting each other.

[0059] In advantageous embodiments the contact free measurement system is or at least comprises a laser based system, wherein during use at least one laser beam is projected onto a surface of the plate while calculating speed and / or distance based on reflection of the at least one laser beam, allowing accurate measurement under different circumstances. Preferably a laser surface velocimeter (LSV) is used.

[0060] Fig. 2 schematically shows a roller press system 11, comprising a roller press 12 and a computer system 13, connected to or part of the roller press 12. With the computer system 13 at least the roller press 12 can be controlled.

[0061] As is schematically shown in the drawings, such as in fig. 2, a measuring system 14 is provided, connected to or connectable to the computer system 13. The measuring system 14 is here shown as an electronic measuring system 14, such as a contact free measuring system 14, for measuring a radius R or diameter D of the plate 1 when being rolled towards and into the final shape, as will be described. Radius and / or diameter are assessed in relation to a longitudinal axis X - X extending perpendicular to the plane of drawing in fig. 2 - 10, central to the circular cross section, and in fig. 12 said axis X - X extends through the centers Ci, C2 of both circular ends 27, 28 of the section 2.

[0062] Fig. 2A shown schematically a practical embodiment of a contact free measurement system 14, designed as a laser based measurement system, especially a laser surface velocimeter (VSL), with which the speed can be measured with which a plate 1 passes alongside the measurement head 14A, with which the diameter of the plate can be calculated. Preferably both the distance Q from the measurement head 14A to the surface of the plate 1 is measured and the speed with which the plate moves alongside the measurement head 14A, and / or the diameter of the plate 1. Thus accurately the length of a plate can be measured when rolled to the position in which the ends 7, 8 are close together, and it can accurately be established what length Le of one or both of the ends 7, 8 has to be removed in order to obtain the desired radius or diameter of the rolled plate.

[0063] As can be seen in fig. 2A the measurement head 14A during use emits two laser beams 102 onto the surface 100 of the plate 1, said laser beams converging towards the plate. Such set up is known from the art of laser surface velocimeters (VSL), for measuring relative speed.

[0064] In a desired position during use the said centerline CL, 103 of the head 14A will be perpendicular to the outer surface of the plate 1, improving the accuracy of the measurements. Preferably the position of the measuring system, especially of the measuring head 14A is settable, such that for different diameters of the plate 1 being rolled the position of the center line CL can be adjusted, preferably automatically. Preferably also the distance Q can be set, for optimizing the accuracy of the measurement and adjusting during rolling to smaller diameters.

[0065] As is schematically shown in fig. 1 at least one and preferably at least two positions are marked on a surface of the plate 1, by appropriate markings 106, close to one or both opposite ends 7, 8 of the plate. These markings 106 are preferably light reflective, especially for laser light used in measuring, when a laser based measuring system is used. Thus it can easily be discerned when one of said ends 7, 8 reaches a given position, or passing such position, especially a position opposite the measuring device 14. Thus an appropriate starting and stopping position for rotating the plate can be defined.

[0066] Furthermore a roller press system comprises a system 20 for removing an edge portion 6, as will be described. The system 20 can preferably be connected to and / or controlled by the computer system 14, and can for example be or comprise but is not limited to a milling device 21. Alternatively for example the system 20 can be or comprise at least a cutting device, such as but not limited to a saw, water jet cutter, plasma cutter or the like.

[0067] In embodiments, as for example schematically shown in fig. 15, the system 20 can comprise two such milling devices or other cutting devices 21, in side by side relationship, preferably at an adjustable mutual distance, such that simultaneously edge portions 6 can be removed from both opposite ends 7, 8, based on the measurement. This can be advantageous for providing straight, parallel ends 7 A, 8 A to be welded together, even if the ends 7, 8 are not parallel after rolling. Obviously such parallel edges 7 A, 8A can also be obtained by using a single device 21 twice.

[0068] The computer system 13 comprises or is fed with at least one of a desired diameter D2, a desired radius R2 or a desired circumferential length L2, desired for the tubular section 2 to be made, schematically represented in fig. 2 by data file 15. It will be clear that for any tubular section radius R and diameter D are related to each other as 1:2, whereas the circumferential length L will be related to the diameter D as L = D * n (circumference is diameter times pi) and thus for the final tubular foundation pile section 2 the final or desired length L2 after removal of said at least one edge portion 6 will be equal to the desired diameter D2 times n. In a method of the disclosure a plate 1 is entered into the roller press 12, preferably in a flat state, in the length direction 3, and is rolled using the roller press 12, in a known manner. In this embodiment the roller press has three rollers 16, one at an inside surface 9, two at an opposite outside surface 10. It will be clear however that also a different number of rollers can be provided, for example four, wherein two rollers 16 will be at the inside surface 9, two at the outside surface 10. By gradually forcing the rollers 16 closer together during rotation of the rollers 16 in the direction RD, continuously in the same direction or reciprocally clockwise and counterclockwise, the plate 1 will be curved, as is known in the art. The opposing ends 7, 8 are thereby forced closer together. It will be noted that in the embodiments shown these ends 7, 8 are not passing each other during rolling, avoiding undesired deformation of the plate and especially avoiding undesired curvature of the plate at a side comprising the one end 7 or 8 compared to the side comprising the other of the ends 8 or 7.

[0069] Methods according to the disclosure are especially suitable for rolling relatively thick, long plates into large pile sections, for example plates having a thickness of 2 to 3 centimeters or more, the pile section having a diameter of up to 7 meters or more, for example up to 10 meters or more. Whereas for such pile sections accuracy shape, especially in roundness of the cross sections especially at opposite ends is to be kept within millimeters, for example less than 10 mm, such as for example less than 8 mm.

[0070] In embodiments of a method of the disclosure, as for example shown in fig. 2 - 5, the plate 1 is rolled to such extent that the opposing ends 7, 8 abut, as is shown in fig. 2. In such embodiment a distance 23 between opposite ends 7, 8 is gradually reduced to zero. Thus the plate 1 forms an initial tubular body with an initial diameter radius Ri and diameter Di. In this position said radius Ri and / or initial diameter Di is measured using the measuring system 14, which can for example be a laser based measuring system, as shown schematically in fig. 3 by arrow 17. The data thus obtained are fed into the computer system 13, in which the measured radius Ri is compared with the desired radius R2 as stored in the computer system 13 and / or the measured diameter Di is compared with the desired diameter D2 as stored in the computer system 13. An algorithm in the computer system 13 is provided for calculating what the length Le of the edge portion 6 to be removed has to be, such that after removal of said edge portion the plate can be rolled further into a shape having the desired diameter D2 when the new or final ends 7 A, 8A abut, as shown in fig. 5. Fig. 4 shows the initial section with the edge portion 6 removed, providing a gap 22 between opposing new ends 7 A, 8A.

[0071] It will be clear that the initial tubular body has a diameter Di and a circumferential length Li. In order to be able to roll the plate 1 further into the desired shape and dimensions, the circumferential length L has to be reduced to Li-Le=L2. This means that the initial diameter Di will be reduced to D2, wherein DI:D2 = (L2+L6) / n : L2 / n. Thus Le = n * (D1-D2). Hence by measuring the diameter Di of the initial tube section it can be assessed easily what length Le has to be removed.

[0072] As can be seen in fig. 5, after removing the edge portion 6 with the relevant calculated length Le, the plate 1 is rolled further to such extent that the gap 22 is closed and the new opposite ends 7 A, 8A are forced into abutment. As discussed, the new opposite ends 7 A, 8A can be a combination of one initial end 7, 8 and one new end 8A, 7A obtained by removing said edge portion 6, or can be two new ends 7 A, 8 A when an edge portion 6 is removed at both initial ends 7, 8 of the plate 1. Each new end 7 A, 8A can be provided with a beveled portion 25, as shown in fig. 5, for improving welding. In the final rolled configuration as shown in fig. 5 the diameter D of the tubular foundation pile section 2 is reduced from Di to the desired diameter D2. It will be clear that alternatively at both opposing ends 7, 8 an edge portion 6 could be removed, the combined edge portions 6 having the length Le as calculated. As discussed, this can especially be advantageous when the edge portions of the plate ends 7, 8 are not parallel after rolling.

[0073] Fig. 6 - 9 shows steps in an alternative embodiment of a method of the disclosure, in which again a plate 1 as shown in fig. 1 is rolled to an initial rolled configuration, as shown in fig. 6. In this initial rolled position opposite initial ends 7, 8 of the plate 1 are spaced apart over a distance 23, forming a gap 22 between said ends 7, 8. In this embodiment by way of example as a measuring instrument 14 is shown at an outside surface 10 of the plate 1, here shown as a contact measuring instrument 14, such as for example a roll or rolling gauge with which the circumferential length of the outer surface 10 can be measured, as well as the width of the gap 22, i.e. the distance 23, for example by rotating the section 2 relative to the gauge with a known speed, such that the time between losing contact and regaining contact with the roll 24 of the measuring device 14 can be measured and used for calculating the length 23 of the gap. It will be directly clear that instead of or combined with this measuring system 14 a contact free measuring system as for example disclosed in and discussed with respect to fig. 2 - 5 can be used, and vice versa.

[0074] Fig. 7 shows the measuring device during use, at an edge of the gap 22. By rotating the section 2 clockwise the roll 24 will pass over the gap 22, measuring the distance 23. In this embodiment the circumferential length L of the plate 1, which may be longer or even shorter or the same length as the initial length Li, is measured, as well as the distance 23, i.e. the width of the gap 22 between the opposing ends 7, 8. The sum of said length L and said distance 23 is compared to the desired circumferential length L2 as stored in the computer system 13. On the bases of this comparison then the length Le of material of edge portion or edge portions 6 is to be removed. In fig. 8 by way of example at both opposing ends 7, 8 an edge portion 6 is shown to be removed, using the system 20, such that the circumferential length L is reduced to the desired circumferential length L2. Obviously similarly only at one end an edge portion 6 can be removed, as is discussed with reference to fig. 2 - 5.

[0075] After removal of the or each edge portion 6 the plate is rolled further, to the position as shown in fig. 9, in which the new opposing ends 7 A, 8A abut, and the diameter D2 is the desired diameter.

[0076] The foundation pile section 2 as shown in fig. 9 is similar to that as shown in fig. 5. As is shown in fig. 10 the opposing, abutting ends 7 A, 8A can be welded, especially at least tack welded using a welding tool 26, which may be a separate tool or can be a tool controlled by the computer system 13. In embodiments also the ends 7 A, 8 A can be line welded using said or a similar welding tool 26, forming a weld 27 as shown in fig. 10.

[0077] In fig. Il a plate 1 is shown for forming a truncated conical foundation pile section 2, the plate 1 being trapezoid in shape. At a first side 27 the plate 1 has an initial length Li, at the opposite second side an initial length LIA, which is shorter. Again in fig. 11 an edge portion 6 is shown, delimited by the striped line.

[0078] A plate 1 of fig. 11 can be rolled and welded into a truncated conical foundation pile section 2, for example using a method similar to fig. 2 - 5 or in an embodiment similar to fig. 6 - 9, to be welded, for example as shown in fig. 10.

[0079] As can be seen in fig. 12 by way of example, similar to fig. 2 the plate 1 can be rolled to an initial tubular body having opposite ends 7, 8 abutting. The measuring system 14 can be used for measuring the initial diameter Di at a first end 27 of the section 2, whereas a with the same or a different measuring system 14 the initial diameter DIA can be measured at the opposite second end 28 of the section. In this embodiment a data file 15 can have been entered into the computer system 13 comprising desired values for the desired radius R2 and R2A, the desired diameter D2 and D2A and / or the desired circumferential length L2, L2A for the first end 27 and second end 28 respectively. Thus in a way similar to as discussed here before the length Le and L(;\ of both ends of an edge portion 6 can be defined, to be removed in order to by further rolling and welding form a truncated conical foundation pile section 2 having the desired diameters D2 and D2A at the first end 27 and second end 28, which in use normally will be the lower end and the upper end respectively.

[0080] It will be clear that similarly a method similar to fig. 6 - 9 or to fig. 13 and 14 can be used for forming a truncated conical section 2. Also in embodiments it can suffice to measure the radius, diameter and / or circumferential length at one position only, for example at one of the ends 27, 28, or in between them. In embodiments the measurement can be taken at multiple locations.

[0081] Fig. 13 and 14 schematically show a further embodiment of a method and system according to the disclosure, in which after rolling the plate 1 into an initial cylindrical, tubular shape, as shown in fig. 13, wherein a gap 22 is left between the opposite ends 7, 8 of the plate 1. In this embodiment preferably the opposite ends 7, 8 of the plate as originally used are kept. Alternatively an edge portion 6 can be removed from one or both of said opposite ends 7, 8, forming one or two new opposite ends 7 A and / or 8A. At least one of the diameter Di, radius Ri and circumferential length L along a surface 9, 10 of the plate between said opposite ends is measured after rolling the plate, as shown in fig. 13, using the measuring system, here shown by way of example as an electronic measuring system or device 14 as described here before, such as a laser based measuring system. The diameter Di, radius Ri and / or circumferential length L as measured is compared by the computer system 13 with the desired diameter D2, radius D2 and / or circumferential length L as provided in the computer system 13. If the measured value Di, Ri and / or L does not match the desired relevant value D2, R2 and / or L2, the plate 1 is rolled further, until they match. Once the measured value Di, Ri and / or L does match the desired relevant value D2, R2 and / or L2, the distance 23 between said opposite ends 7, 8 (or 7 and 8A, 7A and 8A or 7A and 8) is measured, using the same or a different measuring system 14.

[0082] In this embodiment a new edge portion 30 is provided, having a curvature matching the curvature of the rolled plate 1 and having a length L30, measured in the circumferential length direction, matching the distance 23 and having a width W, extending in fig. 13 in a direction perpendicular to the plane of drawing, preferably matching the width W of the plate 1. The edge portion is preferably made of the same material, and having the same thickness T as the plate 1. The new edge portion 30 is fitted in the gap 22, as shown in fig. 14, between the ends 7, 8 (or 7 and 8A, 7A and 8A or 7A and 8) and welded to the opposite ends of the plate 1 using a welding system 21, preferably controlled by the computer system 13.

[0083] In embodiments according to for example fig. 13 and 14, a plate 1 can be used having an initial length smaller than the desired circumferential length L2 of the section 2 to be formed. In fig. 13 and 14 the length L30 is shown relatively small compared to the circumferential length L2 of the entire section 2, but this can obviously also be larger, for example such that it includes an angle of between 1 and 90 degrees, such as for example between 1 and 45 degrees, such as for example between 2 and 30 degrees, which angles are only provided by way of example.

[0084] Fig. 15 schematically shows an alternative embodiment of a method and system for rolling a plate 1, similar to the system of e.g. fig. 1 - 14, wherein the measurement system 14 is designed as a laser based measurement system, especially a laser surface velocimeter (VSL), with which the speed can be measured with which the plate 1 passes alongside the measurement head 14A, with which the diameter of the plate can be calculated. Preferably the reflective surfaces 106 are used for starting and stopping a measurement. Preferably both the distance Q from the measurement head 14A to the surface of the plate 1 is measured and the speed with which the plate moves alongside the measurement head 14A, and / or the diameter of the plate 1. Thus accurately the length of the plate can be measured when rolled to the position in which the ends 7, 8 are close together, and it can accurately be established what length Le of one or both of the ends 7, 8 has to be removed in order to obtain the desired radius or diameter of the rolled plate.

[0085] As can be seen in fig. 15 the center line CL of the measuring head 14A is coaxial with the centerline of the rolled plate 1, such that it passes substantially through the center Ci of the plate. This is a desired position since therein the said centerline CL will be perpendicular to the outer surface of the plate, improving the accuracy of the measurements. Preferably the position oif the measuring system, especially of the measuring head 14A is settable, such that for different diameters of the plate 1 being rolled the position of the center line CL can be adjusted, preferably automatically.

[0086] Instead of direct measurement of the radius, diameter or circumference of a section 2 an indirect measurement system can be used, for example a digital imaging system, wherein a digital image of an end of the initial rolled section, as for example shown in fig. 2, fig 6 or fig. 12 is taken, from which image the relevant measurement is taken and used in the computer system as described. It will be understood that an imaging system similar to that as disclosed in fig. 2 - 5 can also be used for taking outside measurements, whereas a system similar to that as shown in fig. 6 - 9 could also be used for taking inside measurements of a section.

[0087] As schematically indicated in fig. 1 by lines 30 a plate 1, which is here before described by way of example as an integral plate 1, a plate for use in a method or with a system of the disclosure can also be assembled from a series of two or more plate sections, which may be welded together, for example as indicated by said lines 30, the series provided between opposing ends 7, 8. Similarly plate sections could be provided in series in the width direction 4.

[0088] In a method for forming a foundation pile section according to the disclosure, with a desired diameter and circumference, wherein the section has a circular cross section perpendicular to a longitudinal axis of said section, a plate having a width direction and a length direction perpendicular to the width direction, is rolled in said length direction into a cylindrical or frusto-conical shape. The plate is rolled such that opposite ends of said plate are brought in an adjacent position, wherein during and / or directly after rolling a circumference and / or a diameter cq radius of the rolled plate are assessed. In embodiments an edge portion of the plate at at least one of said adjacent opposite ends is removed after said first rolling, where after said then adjacent opposite ends are brought together and welded together. To that end the plate is rolled further, preferably in the same press. In embodiments the plate is rolled to an end position in which the desired diameter, radius and circumferential length of the full section is reached, in which a gap is left open between opposite ends, which gap is then filled by a new edge portion made to size.

[0089] The diameter or radius or circumference as assessed, especially as measured prior to removing the or each edge portion or adding a new edge portion is also referred to as a radius, diameter or circumference as is. A radius, diameter or circumference or circumferential length as provided in the computer is considered a set or desired radius, diameter or circumference. In embodiments in which a new edge portion is added the measured diameter, radius or circumference, when measured including the gap, is to be the same as the desired diameter, radius or circumference.

[0090] It will be clear that the initial length of a plate 1 to be used in a method of the present disclosure in which an edge portion is removed will be larger than the length L2 necessary for forming the final tubular foundation pile section 2, in order to be able to remove an edge portion after rolling. In embodiments in which a new edge portion is to be added the initial length is preferably smaller that the full circumferential length of the section to be formed.

[0091] With methods according to the disclosure it has been found that even very large diameter foundation pile sections, for example with diameters in the range of ten meters or more, can be made relatively easy within prescribed tolerances of millimeters.

[0092] In the embodiments shown the steps of first rolling, assessment of at least one of the radius, diameter and circumference, removing of at least one edge portion or adding a new edge portion, possibly further rolling and welding are disclosed as performed in and by the same roller press system. It is however also possible to remove the plate from the roller press between steps, for example for removing the or each edge portion, and replacing the plate afterwards into the same or a different press. Similarly for example welding can be performed outside the roller press.

[0093] The invention is by no means limited to the embodiments disclosed herein by way of example only. Many amendments can be made within the concept of the disclosure, including combinations of some or all of the features of the methods and structures as disclosed.

[0094] For example, in the drawings the or each a section has either a constant diameter D over its length along the axis X - X, for a cylindrical section 2, or a continuously reducing diameter D over its length for a frusto conical section. Depending on the rolls and the initial dimensions of the plate used this can however also be chosen different. In the embodiment shown the measuring systems are shown as wired to the computer system. It is however also possible to transfer data from the measuring system differently, for example wireless or by obtaining the data in a separate measuring system, storing said data temporarily in the measuring system, and then transferring the data from the measuring system to the computer system.

Claims

Claims1. Method for forming a foundation pile section with a desired diameter and circumference, wherein the section has a circular cross section perpendicular to a longitudinal axis of said section, wherein a plate having a width direction and a length direction perpendicular to the width direction, is rolled in said length direction into a cylindrical or frusto-conical shape, such that opposite ends of said plate are brought in an adjacent position, wherein during and / or directly after rolling a circumference and / or diameter cq radius of the rolled plate are assessed, whereby: an edge portion of the plate at at least one of said adjacent opposite ends is removed, based on said assessment, where after said then adjacent opposite ends are brought together and welded together, or an new edge portion is welded between said opposite ends, based on said assessment.

2. Method according to claim 1, wherein the adjacent opposite ends: are in abutment with each other during assessment of the circumference and / or diameter of the rolled plate prior to said removing of the edge portion; or are held spaced apart over a known and / or measured distance during assessment of the circumference and / or diameter of the rolled plate, prior to said removing of the edge portion or welding said new edge portion to said opposite end.

3. Method according to any one of the preceding claims, wherein the diameter and / or circumference are assessed by measuring the diameter of the rolled plate and / or circumference of the plate between the said opposing ends at at least one cross section and the width of a gap between said opposing ends, and calculating the difference between at least one of thediameter and the circumference as is and the diameter or circumference as desired.

4. Method according to any one of claims 1 to 3, wherein the diameter and / or circumference are assessed by, during and / or after rolling, measuring the diameter or radius of the plate at at least one cross section and the width of a gap between said opposing ends, and calculating the difference between at least one of the diameter or the circumference as is and the diameter or circumference as desired, removing an edge portion at at at least one end of said plate and rolling the plate further to a position in which the ten opposing ends meet.

5. Method according to any one of the preceding claims, wherein the plate is rolled using a roller press, connected to or comprising a computer system, wherein a desired diameter and / or circumference is set in said computer system, wherein an assessed diameter and / or circumference is compared with said set value for the diameter and / or circumference, wherein based on said comparison: a length of said edge portion in the length direction of the plate is defined and said edge portion is removed based on said defined length of the edge portion; or a length of a new edge portion in the length direction of the plate is defined and said new edge portion is formed and fitted in between opposite ends of the plate.

6. Method according to any one of the preceding claims, wherein the plate is formed by welding two or more sub plates together along adjacent sides extending in said width direction of said plate, such that said at least two sub plates are provided next to each other between said opposing ends of the plate.

7. Method according to any one of the preceding claims, wherein the length of the plate, measured in said length direction along a surface of theplate between said opposite ends, prior to said rolling, is larger than a circumferential length of the plate after said welding.

8. Method according to any one of the preceding claims, wherein a roller press is used for rolling the plate into said cylindrical shape, wherein at least one of measuring the diameter or radius and / or circumference, removing of the at least one edge portion or welding a new edge portion to the plate and welding said opposing ends together is performed while the plate is in said roller press.

9. Method according to any one of the preceding claims, wherein the diameter and / or the circumference is assessed at or along an inward facing surface of the plate and / or at or along an outward facing surface of the plate.

10. Method according to any one of the preceding claims, wherein the diameter or radius or circumference is assessed be measuring electronically.

11. Method according to anyone of the preceding claims, wherein a plate is rolled which prior to rolling has a length of at least 20 meters, prior to removing of said at least one edge portion, and a width of at least 4 meters and a thickness of at least 10 mm.

12. Method according to any one of the previous claims, wherein the opposite ends of the plate are prevented from passing each other during rolling.

13. Method according to any one of the previous claims, wherein the length of the plate and / or the diameter and / or radius of the plate during rolling are assessed, using at least a laser based, contact free measuring system, preferably a laser surface velocimeter (LSV) measuring speed of the plate.

14. Roller press system for pressing a plate into a cylindrical or frusto conical shape, wherein the roller press system comprises: a roller press: a computer system, part of or connected to the roller press; and at least one measurement system for:measuring at least one of a diameter, radius and circumference of a plate while being or after having been rolled in said roller press, and feeding data concerning said diameter, radius and / or circumference into the computer system; and measuring a distance between two opposing longitudinal ends of the plate, and feeding data concerning said distance into the computer system, wherein a desired diameter, a desired radius and / or a desired circumference of a cylinder rolled from said plate are stored in said computer system, wherein the computer system is construed for assessing an as is diameter, radius and / or circumference of a cylinder rolled from the plate as is, comparing said as is diameter, radius or circumference with the desired diameter, radius or circumference as stored in said computer system and calculating, based on said comparison, a length of an edge portion of the plate at at least one of said opposite ends to be removed from the plate when having been rolled towards the cylindrical or frusto conical shape or a length of a new edge portion to be welded between said opposite ends when having been rolled towards the cylindrical or frusto conical shape.

15. Roller press system according to claim 14, wherein the computer system is further programmed to operate a device for removing said at least one edge portion.

16. Roller press system according to any one of claims 14 or 15, wherein the computer system is further programmed to operate the roller press after removal of said at least one edge portion, for forcing opposite ends of the remaining plate against each other.

17. Roller press system according to claim 16, wherein the computer system is further programmed to operate a welding system, for welding said opposite ends of the remaining plate together, at least by tack welding.

18. Roller press system according to any one of claims 14 - 17, wherein the computer system is further programmed to operate a weldingsystem for welding the said new edge portion to at least one of said opposite ends and preferably to both of said opposite ends.

19. Roller press system according to any one of claims 14 - 18, wherein the measuring system comprises at least a laser baser measurement system, especially a laser surface velocimeter.

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