Helically Corrugated Pipe Forming with Slip-Clutch Friction Control
Solution Overview
Problem
The existing production processes for helically corrugated metal pipes, particularly those using polymer coated steel, face challenges in maintaining the integrity of the metal sheet and its coating, leading to polymer damage and making the production of higher gauge pipes commercially unviable due to high labor costs and defect rates.
Innovation Solution
A system and method utilizing progressive profile formation with a series of tooling stands that gradually form box-shaped corrugations, incorporating a slip-clutch arrangement to reduce friction and prevent polymer tearing, allowing for the production of higher quality helically corrugated metal pipes with reduced polymer damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional roll forming process is used to produce helically corrugated metal pipe, then production efficiency is maintained, but polymer coating damage occurs and manufacturing precision deteriorates
Solution Approach 1:
The forming process is divided into multiple sequential tooling stands (first, second, and third stands) that progressively form the corrugations in stages. This segmentation allows each stand to perform a specific forming function with controlled pressure, preventing polymer coating damage while maintaining production efficiency.
Solution Approach 2:
The first tooling stand performs preliminary forming of the corrugations before subsequent stands complete the process. This preliminary action gradually shapes the metal strip without applying excessive force that would damage the polymer coating, thereby improving manufacturing precision.
2Manufacturing precision
If additional tooling stands are added to flatten curved areas and form edges, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The third tooling stand combines multiple functions: it completes the corrugation forming process, flattens curved areas, and forms edges for lock seaming. By merging these operations into a single integrated stand, the patent achieves high manufacturing precision without proportionally increasing device complexity.
Solution Approach 2:
The third tooling stand serves multiple purposes in the forming process, acting as both a finishing corrugation tool and an edge-forming tool. This multi-functionality reduces the need for separate dedicated tooling stands, thereby limiting the increase in device complexity while maintaining precision.
3Strength
If lock seaming or welding is used to join edges, then pipe structural strength is achieved, but harmful factors increase due to polymer damage
Solution Approach 1:
The patent modifies the forming parameters (pressure, speed, tool geometry) in the third tooling stand to create optimized edges that are ready for lock seaming. By controlling these parameters, the edges are formed with sufficient strength for joining while minimizing polymer coating damage that would compromise the integrity of the subsequent welding or crimping process.
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 approach enables the commercial viability of producing 14, 12, and even 10 gauge helically corrugated polymer coated metal pipes with a significantly reduced surface area polymer defect rate, below 2%, by maintaining the integrity of the metal sheet and its coating.
Implementation Method 1
incorporating a slip-clutch arrangement to reduce friction and prevent polymer tearing
Data Source
AI summary
A pipe manufacturing system and method for producing helically corrugated metal pipe is provided. The system and method utilize controlled profile formation.