Wedge Adjustment Rings for Pipe Flange Misalignment
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Solution Overview
Problem
The challenge in pipeline construction is the spatial misalignment of flanges due to welding distortion, which requires costly and labor-intensive on-site adjustments without suitable machine tools, complicating the assembly process.
Innovation Solution
The use of wedge-shaped adapter rings with angularly offset contact surfaces, allowing for radial centering and compensation of axial, angular, and parallel offsets between flanges through rotation and material bonding, enabling flexible offset compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to compensate for flange offset, then alignment accuracy can be achieved, but the process becomes costly and labor-intensive requiring on-site machine tools
Solution Approach 1:
The offset compensation is divided into multiple discrete adapter rings, each with a specific wedge angle. Instead of using a single complex adjustment mechanism, the total angular offset is segmented into several smaller angular corrections provided by individual rings, simplifying the assembly process while maintaining precision.
Solution Approach 2:
The adapter rings are pre-manufactured with precise wedge angles in a controlled factory environment rather than being adjusted on-site. This preliminary preparation of the correction components eliminates the need for expensive on-site machine tools and complex adjustment procedures during installation.
2Adaptability or versatility
If multiple adapter rings are used to compensate for offset, then flexibility in compensating different offset types is improved, but the number of components and assembly steps increases
Solution Approach 1:
The adapter rings are designed with a universal interface that allows them to compensate for multiple types of offsets (angular, axial, parallel) through different rotation orientations. The same basic ring design can address various misalignment scenarios by rotating the rings to different angular positions, eliminating the need for specialized components for each offset type.
Solution Approach 2:
The adapter rings feature an asymmetric wedge shape with different thicknesses at opposite sides. This asymmetry enables the rings to provide angular correction when rotated to specific orientations, while the same rings can compensate for axial or parallel offsets by rotating them to different orientations, achieving multi-functionality from a single component design.
3Ease of operation
If on-site adjustment work is performed without suitable machine tools, then installation can proceed, but the quality and reliability of the connection deteriorates
Solution Approach 1:
All precision adjustments are performed in advance during factory manufacturing of the adapter rings. The rings are machined with exact wedge angles and tolerances in a controlled environment with proper equipment, ensuring high reliability without requiring sophisticated machine tools at the installation site.
Solution Approach 2:
The adapter rings are designed to be self-aligning through their wedge geometry and tapered surfaces. During installation, the rings automatically position themselves to compensate for the offset without requiring complex adjustment procedures or specialized tools on-site, maintaining both ease of operation and connection reliability.
Data Source
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AI summary
The invention relates to an arrangement (ARR) for equalizing an offset (OFT) between two pipe flanges (FLG), comprising: an arrangement (ARR) for equalizing an offset (OFT) between two pipe flanges (FLG), comprising: adjustment rings (AJR), each having a recess (HOL) which extends along an axis (X) and about which a ring material (AMT) extends in a circumferential direction (CDR), wherein at least two of the adjustment rings (AJR) have two contact surfaces (CSF), the contact surfaces (CSF) having flat, substantially circular contact surfaces (CSF) at least along circular tracks concentric to the axis (X), a cross section of the ring material (AMT) having a varying axial ring material thickness (ART) in the circumferential direction (CDR) such that at least two of the adjustment rings (AJR) comprise a wedge shape having an angular offset (AOF) of the two contact surfaces (CSF) relative to each other. In order to be able to flexibly compensate for different offset phenomena, according to the invention, the arrangement (ARR) comprises at least three adjustment rings (AJR).