Hot Induction Pipe Bending for Homogeneous Bend Properties
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Solution Overview
Problem
Current induction bending methods for large diameter pipes result in inhomogeneous grain distribution and mechanical properties, leading to potential points of failure and the need for post-bend heat treatments.
Innovation Solution
A system and method that includes an induction ring to heat an annular band of the pipe wall, quenching rings to direct fluids concurrently to both inner and outer surfaces, and a processor to control the heating and quenching process, ensuring uniform temperature treatment across the pipe length and thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If induction bending heats only the pipe segment being bent, then the bending process is efficient and localized, but it creates material transition zones with inhomogeneous grain distribution
Solution Approach 1:
The heating process is segmented into three distinct zones: a first heating zone ahead of the bend, a second heating zone at the bend location, and a third heating zone behind the bend. This segmentation allows each zone to be heated independently to achieve homogeneous grain distribution throughout the entire pipe length while maintaining bending efficiency.
Solution Approach 2:
The pipe is pre-heated in the first heating zone before the actual bending occurs. This preliminary heating action ensures that the material is at the appropriate temperature for homogeneous grain structure formation before the bend is applied, preventing inhomogeneous grain distribution in the transition zones.
2Device complexity
If conventional bending creates transition zones, then the bending process is simpler, but reliability decreases due to inhomogeneous mechanical properties
Solution Approach 1:
Different sections of the pipe receive different heating treatments tailored to their specific requirements. The first end portion, bend portion, and second end portion are each heated according to their specific needs to achieve uniform grain distribution throughout, thereby improving reliability without significantly increasing overall process complexity.
3Extent of automation
If inhomogeneous grain distribution occurs, then the bending process requires less control, but post-bend heat treatment becomes necessary
Solution Approach 1:
The heating process continues uninterrupted through all three zones (before, during, and after bending) to maintain homogeneous grain distribution throughout the entire pipe. This continuous heating action eliminates the need for post-bend heat treatment by ensuring uniform metallurgical properties are achieved during the bending process itself.
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 reduces or eliminates transition zones, achieving greater homogeneity in metallurgical and mechanical properties along the pipe bend, thereby enhancing reliability and potentially eliminating the need for post-bend heat treatments.
Implementation Method 1
an induction ring configured to heat an annular band of a wall of the pipe
Implementation Method 2
heating, with an induction coil, a first annular band of a wall of a first end portion of a pipe
Implementation Method 3
a first quenching ring configured to direct a first quenching fluid toward an outer surface of the heated annular band in the wall of the pipe; a second quenching ring configured to direct a second quenching fluid toward an inner surface of the heated annular band
Data Source
AI summary
In one embodiment, a method for manufacturing a pipe bend is disclosed, comprising: heating, with an induction coil, a first annular band of a wall of a first end portion of a moving pipe; directing quenching fluid toward an outer and inner surface of the first annular band; heating a second annular band of a wall of a bend portion of the moving pipe; directing the quenching fluid toward an outer and inner surface of the second annular band; decreasing a speed of the pipe while moving the induction coil from stationary and maintaining a relative speed between the pipe and the induction coil substantially constant; heating a third annular band of a wall of a second end portion of the pipe while moving the induction coil; and directing the quenching fluid toward an outer surface and an inner surface of the third annular band while moving the induction coil.