Embossed Pipe Seam Welding with V-Groove Sheet Forming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for manufacturing embossed pipes using a pipe mill face challenges such as deformation of embossed patterns, dimensional instability, and inability to weld seam portions due to mismatched concave-convex curved surfaces, leading to poor product quality and low productivity.
Innovation Solution
An embossed pipe manufacturing apparatus that includes an uncoiler, centering guide roller, and a pipe mill with an embossing machine featuring an upper roller with a relief embossing pattern and a lower roller with an intaglio embossing pattern, which forms a V-shaped groove for welding, allowing precise alignment and fusion of embossed metal sheets to create a neatly finished pipe.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If embossed pipe is formed using embossed metal sheet with concave-convex curved surface and then seam portion is welded, then embossed pattern is formed on pipe surface, but welding is impossible due to mismatch of seam portion
Solution Approach 1:
The invention performs preliminary flattening of the embossed metal sheet before welding, and preliminary formation of V-shaped grooves at the seam portions. This preliminary action removes the concave-convex curvature that prevents welding, allowing the seam portions to be properly aligned and welded while maintaining the embossed pattern on the pipe surface.
Solution Approach 2:
The invention segments the embossed metal sheet at the seam portions to form V-shaped grooves, separating the welding preparation from the main embossed surface. This segmentation allows the seam areas to be flattened and prepared for welding independently from the decorative embossed pattern areas.
2Shape
If conventional pipe mill is used to curve and round embossed metal sheet, then pipe shape is formed, but embossed pattern deforms and dimensional stability is lost
Solution Approach 1:
The invention performs preliminary flattening of the embossed metal sheet before it enters the pipe mill for curving and rounding. This preliminary action stabilizes the dimensions and prevents deformation of the embossed pattern during the pipe forming process, maintaining manufacturing precision while achieving the desired pipe shape.
3Ease of manufacture
If seam portion is welded without V-shaped groove, then welding process is simpler, but weld quality is poor and scars are visible
Solution Approach 1:
The invention performs preliminary formation of V-shaped grooves at the seam portions before welding. This preliminary groove formation ensures proper weld penetration and quality, preventing visible scars while maintaining an efficient welding process. The V-shaped grooves are created during the flattening stage, making the subsequent welding straightforward.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Disclosed are an embossed pipe manufacturing apparatus including an uncoiler configured to provide a flat metal sheet, a centering guide roller configured to guide the flat metal sheet supplied from the uncoiler to an embossing machine located at the rear thereof, the embossing machine being configured to emboss the flat metal sheet supplied via the centering guide roller in order to form an embossed metal sheet, and a pipe mill configured to curve and round the embossed metal sheet supplied through the embossing machine in order to manufacture an embossed pipe having a weld seam portion formed in the longitudinal direction, the pipe mill also being configured to weld the weld seam portion of the embossed pipe manufactured as described above in order to complete the embossed pipe, and an embossed pipe manufacturing method including a first step of supplying a flat metal sheet to the embossing machine from the uncoiler via the centering guide roller, a second step of embossing the flat metal sheet using an embossing press roller of the embossing machine to form an embossed metal sheet, and a third step of supplying the embossed metal sheet to the pipe mill to manufacture an embossed pipe having a weld seam portion formed in the longitudinal direction through curving and rounding processes and welding the weld seam portion of the embossed pipe to complete the embossed pipe.