Flexible Pipe Armor Anchorage Welding for High Axial Tension
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Solution Overview
Problem
Existing methods for attaching transverse anchorage elements to armor elements in flexible pipes require significant time and skilled labor, and may not provide a robust enough fastening to withstand high axial tensions and frequent tension cycles, especially in deep-water applications.
Innovation Solution
A method involving an attachment device that melts and forges anchorage elements onto armor elements within a cavity, forming a weld connection, which can include heat treatment and neutral gas diffusion to enhance the weld's strength, allowing for rapid and robust attachment of anchorage elements with a high tensile strength steel base.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If longitudinal welding is used to attach anchorage elements to armor elements, then the attachment strength is improved, but the manufacturing time and skill requirement increase significantly
Solution Approach 1:
The patent replaces the mechanical welding process with a friction-based attachment mechanism. The protrusion element is inserted into the recess element and secured through friction and geometric interlocking, eliminating the need for longitudinal welding operations. This substitution dramatically reduces manufacturing time while maintaining attachment strength through the friction fit and geometric constraints.
Solution Approach 2:
The patent changes the attachment mechanism from a thermal-structural process (welding) to a mechanical-friction process. By modifying the geometry of the anchorage elements (protrusion and recess shapes) and utilizing friction forces, the attachment achieves sufficient strength without the time-consuming welding operation. The parameter change involves transitioning from temperature-dependent bonding to force-dependent mechanical interlocking.
2Strength
If longitudinal welding is used to attach anchorage elements, then the attachment strength is improved, but the complexity of the manufacturing process and skill requirement increase
Solution Approach 1:
The patent replaces the complex welding system with a simple friction-based mechanical attachment system. Instead of requiring welding equipment, qualified welders, and complex process control, the invention uses geometrically designed protrusion and recess elements that self-lock through friction and shape complementarity. This dramatically simplifies the manufacturing process and reduces skill requirements.
Solution Approach 2:
The anchorage elements are designed to self-attach through their geometric configuration. The protrusion element fits into the recess element and automatically secures itself through friction and geometric interlocking, without requiring external welding operations or skilled intervention. The system serves itself by using the inherent mechanical properties of the shaped elements to create a secure attachment.
3Strength
If more anchorage elements are attached to each armor element, then the resistance to axial tension is improved, but the manufacturing time and complexity increase
Solution Approach 1:
The patent divides the anchorage function into two separate elements: a protrusion element and a recess element. This segmentation allows each element to be optimized independently for its specific function, and the assembly process becomes simpler than attaching multiple separate anchorage features. The divided design achieves superior tension resistance through the interlocking geometry while maintaining manufacturing efficiency.
Solution Approach 2:
The patent creates a composite anchorage system by combining the protrusion element and recess element into an integrated attachment mechanism. This composite approach, where two elements work together through friction and geometric interlocking, provides superior tension resistance compared to single-element designs, while the modular nature maintains manufacturing efficiency through simplified assembly procedures.
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 enables a quick and robust attachment of anchorage elements, reducing the time and skill required for the process while providing a strong weld with high mechanical shear strength, effectively addressing the challenges of high axial tensions and frequent cycles in deep-water applications.
Implementation Method 1
the melting of one end of the anchorage element facing the armor element and of a region of the armor element facing the anchorage element, inside the cavity of the attachment device
Implementation Method 2
the forging of the anchorage element transversely on the armor element, using the attachment device
Implementation Method 3
the formation of a weld connecting the anchorage element and the armor element
Data Source
AI summary
A method for attaching at least one transverse anchorage element to an armor element intended to be housed in an end-fitting of a flexible pipe, including the following steps: the supply of an attachment device accepting an anchorage element; the bringing of an opening to face the armor element; the melting of one end of the anchorage element facing the armor element and of a region of the armor element facing the anchorage element, inside the cavity of the attachment device; the forging of the anchorage element transversely on the armor element, using the attachment device; and the formation of a weld connecting the anchorage element and the armor element.