Multi-Layer Pipe Pre-Bending and Integral Joining
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Solution Overview
Problem
Existing methods for producing multilayer large pipes face inefficiencies in production effort and lack integral connections, with limitations in material selection and design flexibility due to nonpositive, frictional engagement and complex stop edge embodiments.
Innovation Solution
A method involving pre-bending of support and liner sheets to specific initial bending radii, followed by integral joining along longitudinal edges and shaping with nonpositive, frictional engagement, and subsequent welding to close gaps, allowing for various bending machines and materials with different thicknesses and widths for enhanced design and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If flat sheet metal plates are laid onto one another and attached in alternating fashion in multiple steps with stop edges, then multilayer pipe production is achieved, but production effort and device complexity increase significantly
Solution Approach 1:
The support sheet is pre-bent to a predetermined initial bending radius and equipped with integral connecting elements before the liner sheet is attached. This preliminary preparation eliminates the need for complex stop edge embodiments and multiple attachment steps, thereby reducing production effort and device complexity while maintaining productivity
Solution Approach 2:
The complex stop edge embodiment and positioning steps are extracted and eliminated from the production process. Instead, a simplified approach using integral connecting elements on a pre-bent support sheet is employed, reducing the number of production steps and overall process complexity
2Adaptability or versatility
If nonpositive, frictional engagement is used between material layers, then material selection flexibility is improved, but integral connection and production efficiency are compromised
Solution Approach 1:
The support sheet is pre-bent to a predetermined initial bending radius before the liner sheet is attached. This merging of the bending operation into the preparation phase allows for more efficient production while maintaining the advantages of nonpositive, frictional engagement between material layers
Solution Approach 2:
The support sheet undergoes preliminary bending to a predetermined initial bending radius before the liner sheet is attached. This advance preparation streamlines the production process and improves efficiency while preserving material selection flexibility
3Productivity
If pre-bending to predetermined initial bending radius is performed, then production efficiency and design flexibility are improved, but additional production steps are required
Solution Approach 1:
The bending operation is merged into the preparation phase by pre-bending the support sheet to a predetermined initial bending radius before liner attachment. This integration eliminates the need for separate bending steps later in the process, thereby improving overall production efficiency without significantly increasing device complexity
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 method improves production efficiency and design flexibility by achieving a high-quality integral connection, preventing bulging, and allowing for stable multilayer pipes with scalable bonding, using materials with varying yield strengths and optimized welding processes.
Implementation Method 1
shaping of the composite of the integrally joined support layer and at least one liner layer to form a slit multilayer large pipe by a bending machine, with nonpositive, frictional engagement in liner regions that are not integrally joined
Implementation Method 2
closing of the remaining gap of the slit multilayer large pipe with a longitudinal seam by welding
Data Source
AI summary
A method for producing a multilayer large pipe having an outer support layer and at least one inner liner layer. Advantages with regard to productivity and the properties of the multilayer large pipe are achieved by the sequence of method steps wherein production of a support sheet is pre-bent to a predetermined initial bending radius for the support layer and at least one liner sheet is pre-bent to a predetermined initial bending radius for the liner layer, placement of the at least one pre-bent liner sheet against the inside of the pre-bent support sheet, with a positioning and parallel alignment of its longitudinal edges extending in the direction of the bending axis in order to form the support layer and the at least one liner layer, there is integral joining of at least one of two longitudinal edges of the at least one liner sheet to the support sheet, shaping of the composite of the integrally joined support layer and at least one liner layer to form a slit multilayer large pipe by a bending machine, with nonpositive, frictional engagement in liner regions that are not integrally joined, and there is closing of the remaining gap of the slit multilayer large pipe with a longitudinal seam by welding.