Flexible Pipe Armor Wire Folding Tool for Work-Hardening Reduction
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Solution Overview
Problem
The existing methods for mounting connection end pieces on flexible tubular pipes used in offshore oil and gas fields face challenges such as arduous manual bending of large and resistant armor wires, lack of reproducibility, and excessive work-hardening, which can reduce the fatigue strength of the anchoring system.
Innovation Solution
A method involving a tool that applies a bending force to armor wires using a sliding application tool, allowing continuous movement along the wire, with a trajectory that varies in angular and axial positions to avoid excessive hardening, and a device with mechanical means for guiding and rotating the tool to facilitate controlled bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual bending of armor wires is performed without special tools, then the process is simple, but the difficulty increases and reproducibility is poor
Solution Approach 1:
A bending tool is introduced as an intermediary device between the operator and the armor wire. The tool includes a bending element that contacts the wire and a handle for operator manipulation, mediating the force application to make bending easier and more controllable without requiring excessive manual strength
Solution Approach 2:
The patent replaces direct manual mechanical bending with a tool-assisted mechanical system. The bending tool uses leverage and mechanical advantage to reduce the manual force required, substituting the operator's direct hand action with a mechanical intermediary that amplifies and directs the applied force
2Productivity
If armor wires are bent manually without control, then the process is fast, but manufacturing precision and reproducibility deteriorate
Solution Approach 1:
The bending tool is designed with pre-configured geometric elements (such as grooves, guides, or shaped bending surfaces) that define the desired bend trajectory and final shape. The operator simply needs to apply force through the tool, which automatically guides the wire through the correct bending path, ensuring consistent results without requiring skilled manual manipulation
Solution Approach 2:
The bending tool allows control over bending parameters such as bend radius, curvature distribution, and final wire configuration. By adjusting the tool's geometry or the operator's application of force through the tool, consistent bending parameters can be achieved across multiple wires, improving reproducibility while maintaining efficiency
3Force
If excessive bending force is applied to armor wires, then the wire can be bent, but work-hardening increases and fatigue strength decreases
Solution Approach 1:
The bending tool is designed to apply force dynamically rather than statically. The tool allows for controlled, progressive bending where the force is applied gradually and can be adjusted during the process. This dynamic application prevents sudden stress spikes that cause excessive work-hardening, while still achieving the necessary bend through controlled deformation
Solution Approach 2:
The bending process using the tool can be performed in periodic stages rather than a single continuous force application. The operator can apply force, pause to allow material relaxation, and then continue bending. This periodic action reduces cumulative work-hardening by allowing stress redistribution and phase recovery in the metal crystal structure during pauses
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method improves the quality of wire folding, reduces work-hardening, and enhances the reproducibility and fatigue strength of the connection end piece, enabling it to withstand significant tensile stresses and variations.
Implementation Method 1
a bending tool (22) intended to apply a bending force (F) to the armor wire (20)
Implementation Method 2
each armor wire (20) is folded back by applying a bending force (F) to each armor wire (20)
Implementation Method 3
during said folding said bending force (F) is applied to each armor wire (20) by means of a sliding application tool (22)
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The invention relates to a method for folding armour wires of a flexible pipe (1), which method is used when mounting a connecting end piece. Folding is carried out with the aid of a device (60) that subjects the wire (20) to a folding force by way of a plier-type tool (22) that surrounds the wire. During folding the pliers slide continuously along the wire, thus preventing excessive work-hardening of the wire. The pliers are moved in space by a co-handling robot (62) controlled by an operator.