Roller-Guided Flange Fitting for Tight-Tolerance Tubular Sections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The process of attaching flanges to tubular sections in large-scale industrial applications is time-consuming and labor-intensive, especially for non-standard geometries, leading to increased costs and challenges in achieving high-precision fit-ups that enhance structural strength and reduce material usage.
Innovation Solution
An automated system comprising tube rollers, a fitting unit with a locating and pusher roller pinch, and a sensing unit with a controller to adjust the radial offset between the flange and tubular section, facilitating faster and more precise attachment of flanges to tubular sections, including multipiece or non-traditional geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual techniques are used for fitting flanges to tubular sections, then flexibility in handling non-standard geometries is maintained, but attachment time and labor costs increase significantly
Solution Approach 1:
The automated flange fitting system is divided into distinct functional modules: a locating roller for positioning, a pusher roller for applying force, and a sensing unit for measurement. Each module performs a specific task, allowing the complex overall process to be managed through simpler, independent components that can be controlled separately.
Solution Approach 2:
The system uses feedback from the sensing unit to automatically adjust the positioning and force application during the fitting process. The controller receives signals about the radial offset and autonomously controls the movement of rollers, enabling the system to self-correct and optimize the fitting process without manual intervention.
2Manufacturing precision
If high-precision fit-up is achieved to increase fatigue strength and reduce material usage, then structural integrity improves, but attachment time and costs increase
Solution Approach 1:
The sensing unit continuously monitors the radial offset between the flange and tubular section during the fitting process. This feedback is transmitted to the controller, which automatically adjusts the positioning of the flange to achieve the desired radial offset, ensuring high-precision fit-up without requiring time-consuming manual measurements and adjustments.
Solution Approach 2:
The system replaces traditional manual measurement and adjustment methods with an automated sensing and control system. The sensing unit provides real-time data, and the controller automatically positions the flange, substituting human skill and time with automated mechanical and electronic systems that achieve higher precision more quickly.
3Productivity
If automated techniques are used for fitting flanges, then attachment speed and precision improve, but system complexity and initial cost increase
Solution Approach 1:
The automated system is divided into distinct functional modules: a locating roller for positioning, a pusher roller for applying force, and a sensing unit for measurement. Each module performs a specific task, allowing the complex overall process to be managed through simpler, independent components that can be controlled separately.
Solution Approach 2:
The automated fitting system is designed to handle various flange geometries and tubular section configurations through programmable control. The same basic mechanism can be adapted to different applications by adjusting control parameters, making the system universally applicable across multiple production scenarios.
4Manufacturing precision
If automated techniques are used for fitting flanges, then dimensional tolerances are tightened, but the complexity of achieving and maintaining precision increases
Solution Approach 1:
The sensing unit continuously monitors the radial offset between the flange and tubular section during the fitting process. This feedback is transmitted to the controller, which automatically adjusts the positioning of the flange to achieve the desired radial offset, ensuring high-precision fit-up without requiring time-consuming manual measurements and adjustments.
Data Source
AI summary
Devices, systems, and methods are directed to automated techniques for fitting flanges to tubular sections used to form tubular structures, such as large-scale structures used in industrial applications (e.g., wind towers and pipelines). As compared to manual techniques for fitting flanges to tubular sections, the devices, systems, and methods of the present disclosure facilitate faster attachment of flanges, which may be useful for achieving cost-effective throughput. By way of further comparison to manual techniques, the devices, systems, and methods of the present disclosure may, further or instead, facilitate achieving tighter dimensional tolerances. In turn, such tighter dimensional tolerances may be useful for forming thinner-walled, lighter, and lower cost tubular structures. Still further or in the alternative, automated techniques for fitting flanges to tubular sections may facilitate attachment of multipiece flanges or other non-traditional flange geometries.