Heavy-Duty Pipe Cladding Roll-On Tool for Uniform Inner Bonding
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Solution Overview
Problem
The production of multi-layer large pipes faces challenges in achieving a stable and uniform connection of the support layer due to out-of-roundness and ovality, especially with large diameters, where existing methods struggle to apply a coating layer effectively without stretching the outer pipe and limiting material choices.
Innovation Solution
A method involving continuous rolling and pressing of the inner support layer with plastic deformation, allowing it to be securely attached to the inner surface of the carrier layer without elongating the outer pipe, enabling the use of diverse metal materials and maintaining the outer pipe's structure integrity, while the coating device applies a stable overlay layer through controlled rolling and axial displacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a rotating support roller and planetary gear-like rolling element are used to apply coating layer, then the coating can be applied to the inner surface of the outer tube, but the contact force becomes inhomogeneous due to out-of-roundness and ovality, making stable bonding difficult
Solution Approach 1:
The patent replaces the mechanical rolling system (support roller and planetary gear) with a hydraulic pressure system. High-pressure fluid is introduced through a nozzle to apply uniform pressure to the coating layer material, forcing it against the inner surface of the outer tube. This substitution eliminates the inhomogeneous contact force problem caused by mechanical rolling on out-of-round pipes, achieving uniform bonding despite geometric imperfections.
2Strength
If the outer tube is stretched to apply the coating layer, then the coating can be secured within the outer tube, but the outer tube's structure integrity is compromised and material choices are limited
Solution Approach 1:
The patent replaces mechanical stretching with hydraulic pressure application. Instead of stretching the outer tube to secure the coating layer, high-pressure fluid forces the coating material against the inner surface. This eliminates the need to compromise the outer tube's structure or limit material choices based on stretchability, allowing use of diverse materials including those with limited ductility.
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 ensures a stable, evenly applied coating layer with minimal elongation of the outer pipe, allowing for the combination of various metal materials and achieving a smooth inner surface, overcoming the limitations of existing methods by maintaining the outer pipe's structure and allowing for a wide range of material selections.
Implementation Method 1
causing local plastic deformation of the inner tube wall
Implementation Method 2
the pressure unit is provided with at least one pressure roller... and with at least one support element counteracting this roller with a support force
Data Source
Figure 1~2
Figure 3~4
Figure 5A~5C
AI summary
The invention relates to a method and a coating device for applying a cladding layer on the inside of a carrier layer during the production of a multilayer heavy-duty pipe, said device comprising a pressure-exerting unit (22) having a force- application unit. A stable application of the cladding layer is achieved in that the coating device comprises a roll-on tool (2) having the pressure-exerting unit (22) and the force-application unit and in that the pressure-exerting unit (22) is provided with at least one pressure roller (20) that has a smaller diameter than the inside diameter of the heavy-duty pipe to be produced and is provided with at least one support element that diametrically counteracts the pressure roller during operation by means of a supporting force.