Sensor-Guided Flange Fit-Up for Non-Standard Tubular Sections
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Solution Overview
Problem
The process of attaching flanges to tubular sections in large-scale industrial applications is time-consuming and labor-intensive, especially for non-standard geometries, leading to increased costs and challenges in achieving high-precision fit-up, which is crucial for structural integrity and material efficiency.
Innovation Solution
An automated system comprising tube rollers, a fitting unit with a locating and pusher roller pinch, and a sensing unit with a controller to adjust the radial offset between the flange and tubular section, facilitating faster and more precise attachment of flanges to tubular sections, including multipiece or non-traditional geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual techniques are used for fitting flanges to tubular sections, then flexibility in handling non-standard geometries is achieved, but the attachment process becomes time-consuming and labor-intensive
Solution Approach 1:
The automated fitting system incorporates self-adjusting mechanisms where the flange is automatically positioned and aligned with the tubular section using sensors and actuators. The system performs self-correction of radial offsets and automatic positioning without continuous manual intervention, thereby maintaining adaptability to various geometries while significantly improving attachment speed and productivity.
2Manufacturing precision
If high-precision fit-up is achieved manually, then fatigue strength and material efficiency are improved, but the time and cost required for attachment increase
Solution Approach 1:
The patent replaces manual mechanical alignment techniques with an automated system incorporating sensors (laser scanners, proximity sensors), computer vision systems, and programmable actuators. This substitution enables high-precision measurement and adjustment of radial offsets and dimensional tolerances automatically, achieving manufacturing precision comparable to or exceeding manual methods while dramatically reducing the time required for fit-up operations.
Solution Approach 2:
The system creates a digital copy or model of the desired flange-tubular section fit-up configuration. Sensors scan the actual components and compare them against the digital model, automatically calculating and executing the precise adjustments needed. This copying approach ensures consistent high-precision results without requiring skilled manual measurement and adjustment, thereby reducing attachment time while maintaining or improving dimensional tolerances.
3Productivity
If automated techniques are used for fitting flanges, then attachment speed and productivity are improved, but the initial equipment cost and system complexity increase
Solution Approach 1:
The automated fitting system is divided into modular functional segments: positioning subsystem, sensing subsystem, control subsystem, and actuation subsystem. Each module performs a specific function and can be independently adjusted or maintained. This segmentation allows the system to achieve high productivity through automation while managing complexity through modular design, making the system more adaptable and easier to implement in existing manufacturing environments.
Data Source
AI summary
Devices, systems, and methods are directed to automated techniques for fitting flanges to tubular sections used to form tubular structures, such as large-scale structures used in industrial applications (e.g., wind towers and pipelines). As compared to manual techniques for fitting flanges to tubular sections, the devices, systems, and methods of the present disclosure facilitate faster attachment of flanges, which may be useful for achieving cost-effective throughput. By way of further comparison to manual techniques, the devices, systems, and methods of the present disclosure may, further or instead, facilitate achieving tighter dimensional tolerances. In turn, such tighter dimensional tolerances may be useful for forming thinner-walled, lighter, and lower cost tubular structures. Still further or in the alternative, automated techniques for fitting flanges to tubular sections may facilitate attachment of multipiece flanges or other non-traditional flange geometries.