Layered Tubular Structures With Mandrel-Controlled Precision
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Solution Overview
Problem
Conventional methods for manufacturing tubular structures, such as pipes, result in products that are heavy, have limited dimensional accuracy, and propagate vibration and noise, while also being difficult to modify or integrate components like insulation zones and sensors.
Innovation Solution
A convolutely wound tubular structure manufacturing process using a mandrel to define the interior shape and size, allowing for precise control of dimensions and the integration of features like insulation, secondary fluid passageways, and couplings, using a layered manufacturing process with sheet metal winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional welded or seamless pipe manufacturing methods are used, then structural strength is achieved, but the tubular structures become heavy and have limited dimensional accuracy
Solution Approach 1:
The tubular structure is manufactured in layered segments using convolutely wound sheet metal layers, allowing precise dimensional control of each layer while maintaining overall structural integrity. This segmented approach enables lightweight construction compared to traditional monolithic seamless or welded pipes.
Solution Approach 2:
The invention uses composite construction with multiple convolutely wound sheet metal layers, potentially combining different materials or treatments in different layers. This allows optimization of weight versus strength characteristics and achieves high dimensional accuracy through controlled layering processes.
2Object-affected harmful factors
If conventional pipe manufacturing methods are used, then basic structural integrity is achieved, but vibration and noise propagation increase
Solution Approach 1:
Multiple convolutely wound sheet metal layers are nested concentrically around a mandrel, creating a layered structure where each layer contributes to vibration and noise dampening. The nested configuration provides inherent damping characteristics while maintaining structural integrity through the combined layers.
Solution Approach 2:
The multi-layer convolutely wound structure creates a composite construction that naturally dampens vibration and noise while maintaining strength. Different layers can be optimized for different functions, with some layers providing structural integrity and others providing dampening characteristics.
3Adaptability or versatility
If conventional pipe manufacturing methods are used, then production efficiency is maintained, but integration of components like insulation zones and sensors becomes difficult
Solution Approach 1:
Components such as insulation zones, sensors, and secondary fluid passageways are integrated into the tubular structure during the convolutely winding process itself, rather than as post-manufacturing additions. This preliminary integration maintains manufacturing efficiency while achieving high adaptability and component versatility.
Solution Approach 2:
The invention merges multiple functions into the single tubular structure manufacturing process, combining structural formation with integration of insulation, sensors, and fluid passageways. This consolidating approach maintains productivity while dramatically improving adaptability and component integration capability.
4Stability of the object's composition
If thick-walled welded tubes are used, then rigidity and consistency are improved, but weight and difficulty of modification increase
Solution Approach 1:
The tubular structure is divided into multiple convolutely wound layers that can be independently controlled during manufacturing. This segmentation provides rigidity and consistency through the multi-layer construction while allowing easier modification compared to monolithic thick-walled tubes, as individual layers can be adjusted or accessed.
Data Source
AI summary
A process for winding a convolutely wound tubular structure having a machine direction, a cross-machine direction coplanar thereto, and a Z-direction orthogonal to both the machine- and cross-machine directions is disclosed.