Interlocking Embossing Roller for Weldable Embossed Metal Pipe
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Solution Overview
Problem
Conventional embossed pipe manufacturing technologies face challenges in maintaining the shape of concave-convex patterns during the manufacturing process, leading to deformation and mismatched seam portions that prevent welding, resulting in gaps and holes in the weld seam, which compromises the product's watertightness and airtightness.
Innovation Solution
A mutual engagement type intaglio-relief embossing press roller is used to form small-width planes at the edges of embossed metal sheets, allowing for precise welding of seam portions and creating a groove to prevent weld scars from being exposed, while maintaining a sophisticated and delicate embossed pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional embossed pipe manufacturing is used, then embossed patterns can be formed on metal pipes, but the concave-convex embossed patterns are deformed during the curving and rounding processes, making welding impossible due to mismatch
Solution Approach 1:
The embossed patterns are formed on the metal sheet before the curving and rounding processes. By preparing the embossed metal sheet in advance with pre-formed patterns, the patterns maintain their shape throughout subsequent manufacturing steps, avoiding deformation that would occur if embossing were done after curving and rounding
Solution Approach 2:
The manufacturing process is divided into distinct stages: first forming embossed patterns on flat metal sheets, then curving the sheets, followed by rounding into pipes. This segmentation allows each process to be optimized independently, with the embossing process completing its work before the metal undergoes deformation in subsequent stages
2Productivity
If conventional embossed pipe manufacturing is used, then pipes can be produced, but weld seam portions have gaps and holes due to pattern mismatch, compromising watertightness and airtightness
Solution Approach 1:
The embossed patterns are preliminarily formed on the metal sheet before curving and rounding. This preliminary embossing ensures that when the sheet is later curved and formed into a pipe, the patterns remain properly aligned at the weld seam, eliminating gaps and holes that would compromise the weld's integrity
Solution Approach 2:
By forming the embossed patterns in advance on the flat sheet, the design anticipates and compensates for the deformation that will occur during curving and rounding. The preliminary embossing creates a pattern layout that accounts for future shape changes, ensuring proper alignment and preventing weld seam defects
Data Source
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AI summary
Disclosed is a mutual engagement type intaglio-relief embossing press roller configured such that, in order to solve a problem in that, at the time of manufacture of an embossed pipe using a pipe mill configured to manufacture a metal pipe, a concave-convex embossed pattern formed on an embossed metal sheet is deformed while the embossed metal sheet passes through male-female engagement type horizontal curving rollers and engagement type horizontal and vertical rounding rollers of the pipe mill, whereby welding is impossible due to mismatch of the concave-convex embossed pattern, the mutual engagement type intaglio-relief embossing press roller forms small-width planes at opposite side edges of the embossed metal sheet in the longitudinal direction so as to be lower than an embossed pattern layer, whereby it is possible to weld a seam portion formed at an embossed metal pipe in the longitudinal direction, and forms a groove in a weld seam portion, whereby it is possible to prevent a weld scar from being exposed outside.