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.
B23K 37/04 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
B23K 37/00 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass
B23K 37/047 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work moving work to adjust its position between soldering, welding or cutting steps
B23K 37/053 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work aligning cylindrical workClamping devices therefor
F16L 23/024 - Flanged joints the flanges being connected by members tensioned axially characterised by how the flanges are joined to, or form an extension of, the pipes
F16L 23/12 - Flanged joints specially adapted for particular pipes
Spiral forming methods can be used to join edges of a rolled material along a spiral joint to form conical and/or cylindrical structures. Alignment of the edges of the rolled material can be controlled in a wrapping direction as the material is being joined along the spiral joint to form the structure. By controlling alignment of the edges of the material as the edges of the material are being joined, small corrections can be made over the course of forming the structure facilitating control over geometric tolerances of the resulting spiral formed structure.
Devices, systems, and methods are directed to mounting an auxiliary component to a tower based at least in part on a force distribution in which a normal force is greater than a shear force exerted by the auxiliary component on a shell of the tower such that the auxiliary component may be held in place relative to the tower without penetrating the shell of the tower. Thus, as compared to mounting techniques requiring penetration of the shell of the tower, this force distribution along the shell of the tower may facilitate mounting the auxiliary component to the tower with little to no impact on cost and/or structural requirements of the tower. Further, or instead, as compared to other mounting techniques, mounting the auxiliary component based at least in part on this force distribution may reduce or eliminate the need for specialized tools, thus facilitating in-field installation of the auxiliary component.
Feeding stock used to form a tapered structure into a curving device such that each point on the stock undergoes rotational motion about a peak location of the tapered structure; and the stock meets a predecessor portion of stock along one or more adjacent edges.
Spiral forming devices, systems, and methods can be used to join edges of a of a stock material, in a curved configuration, along one or more joints to form tubular structures, such as conical and/or cylindrical structures (e.g., frusto-conical structures). A planar form of the stock material can be formed from a plurality planar sheets coupled to one another in an abutting relationship. By controlling relative orientation and shapes of the plurality of planar sheets forming the stock material and/or by controlling a position of a roll bender used to curve the planar form of the stock material into the curved configuration, the curved configuration of the stock material can be controlled through transitions between sheets to facilitate rolling the sheets to a desired diameter with a reduced likelihood of dimples or other errors and to facilitate fit up between adjacent sheets in the curved configuration.
B21C 37/18 - Making tubes with varying diameter in longitudinal direction conical tubes
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
E04H 12/08 - Structures made of specified materials of metal
6.
Control system and method for tapered structure construction
A control system for forming a tapered structure includes a sensor providing feedback for a machine for forming a tapered structure including at least three rolls having at least one bend roll and at least two guide rolls. The guide rolls may include rollette banks having a plurality of rollettes. The machine may also include an adjustment mechanism to position at least one of the rolls, where a diameter of the tapered structure being formed is controlled by relative positions of the rolls. The machine may also include a joining element to join edges of a stock of material together as it is rolled through the rolls to form the tapered structure. The control system may also include a controller to receive feedback from the sensor and to send a control signal based on the feedback to the adjustment mechanism for positioning at least one of the rolls.
Spiral forming methods can be used to join edges of a rolled material along a spiral joint to form conical and/or cylindrical structures. Alignment of the edges of the rolled material can be controlled in a wrapping direction as the material is being joined along the spiral joint to form the structure. By controlling alignment of the edges of the material as the edges of the material are being joined, small corrections can be made over the course of forming the structure facilitating control over geometric tolerances of the resulting spiral formed structure.
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.
B23K 37/00 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass
B23K 37/04 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work
F16L 23/024 - Flanged joints the flanges being connected by members tensioned axially characterised by how the flanges are joined to, or form an extension of, the pipes
F16L 23/12 - Flanged joints specially adapted for particular pipes
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
B23K 37/053 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work aligning cylindrical workClamping devices therefor
B23K 37/047 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work moving work to adjust its position between soldering, welding or cutting steps
Tubular structures (104), systems, and methods are generally directed to support structures having structural properties similar to thick-walled structures while being formed using materials having thickness amendable to rolling and welding and, thus, useful for rapid and cost-effective fabrication. In particular the tubular structures comprise a tubular base (106) and a wrap (108) supported on the base.
According to one aspect, a tubular structure may include a base and a wrap. The base may have a first surface and second surface opposite one another, the first surface defining an elongate cavity, and the base having a tubular shape defining a longitudinal axis extending along the elongate cavity. The wrap may be supported on the second surface of the base, the wrap including a plurality of layers, and each layer having a first longitudinal edge and a second longitudinal edge coupled to one another along a respective spiral seam associated with the given layer and extending about the longitudinal axis of the base.
F16L 9/14 - Compound tubes, i.e. made of materials not wholly covered by any one of the preceding groups
B21B 1/22 - Metal rolling methods or mills for making semi-finished products of solid or profiled cross-sectionSequence of operations in milling trainsLayout of rolling-mill plant, e.g. grouping of standsSuccession of passes or of sectional pass alternations for rolling bands or sheets of indefinite length
B21B 1/28 - Metal rolling methods or mills for making semi-finished products of solid or profiled cross-sectionSequence of operations in milling trainsLayout of rolling-mill plant, e.g. grouping of standsSuccession of passes or of sectional pass alternations for rolling bands or sheets of indefinite length in a continuous process by cold-rolling
B21B 23/00 - Tube-rolling not restricted to methods provided for in only one of groups , e.g. combined processes
B21B 31/00 - Rolling stand structuresMounting, adjusting, or interchanging rolls, roll mountings, or stand frames
B21B 39/34 - Arrangements or constructional combinations specifically designed to perform functions covered by more than one of groups , ,
F16L 9/16 - Rigid pipes wound from sheets or strips, with or without reinforcement
B21B 15/00 - Arrangements for performing additional metal-working operations specially combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills
Feeding stock used to form a tapered structure into a curving device such that each point on the stock undergoes rotational motion about a peak location of the tapered structure; and the stock meets a predecessor portion of stock along one or more adjacent edges.
A method for creating a tapered spiral welded conical structure where the overall shape of the cone is first graphically slit axially and unwrapped, and then a series of construction arcs and lines are created to form the edge lines of a strip that can then be wrapped (rolled) to form a tapered conical structure. The edges of the spirally wound strip can be welded together, and a very large conical structure can thus be achieved. Various construction options are presented from a constant width strip to strip made from straight segments. Equations are given for the formation of the strips to enable those skilled in the art of spiral welded tubing to practice the invention.
E04H 12/08 - Structures made of specified materials of metal
B21C 37/12 - Making tubes or metal hoses with helically arranged seams
B21C 37/18 - Making tubes with varying diameter in longitudinal direction conical tubes
E04H 12/34 - Arrangements for erecting or lowering towers, masts, poles, chimney stacks, or the like
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
Spiral forming devices, systems, and methods can be used to join edges of a of a stock material, in a curved configuration, along one or more joints to form tubular structures, such as conical and/or cylindrical structures (e.g., frusto-conical structures). A planar form of the stock material can be formed from a plurality planar sheets coupled to one another in an abutting relationship. By controlling relative orientation and shapes of the plurality of planar sheets forming the stock material and/or by controlling a position of a roll bender used to curve the planar form of the stock material into the curved configuration, the curved configuration of the stock material can be controlled through transitions between sheets to facilitate rolling the sheets to a desired diameter with a reduced likelihood of dimples or other errors and to facilitate fit up between adjacent sheets in the curved configuration.
B21C 37/18 - Making tubes with varying diameter in longitudinal direction conical tubes
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
E04H 12/08 - Structures made of specified materials of metal
Tube forming methods can be used for efficient transition in the production of tubes having varying thickness. Material used to form consecutive tubes may have the same thickness along a separation plane separating a first discrete section from a second discrete section of the material, and the first discrete section and the second discrete section may each have varying thickness in a feed direction of the material. With such a thickness profile, the first discrete section of the material may be formed into a first cylinder having varying thickness and separated from the second discrete portion as the second discrete section is formed into a second cylinder having varying thickness. In particular, the transition between the first cylinder and the second cylinder may be achieved without scrap and/or interruption, resulting in cost-savings and improvements in production throughput associated with forming tubes having varying thickness.
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
B21C 37/12 - Making tubes or metal hoses with helically arranged seams
B21C 37/26 - Making finned or ribbed tubes by fixing strip or like material to tubes helically-ribbed tubes
B23K 9/032 - Seam weldingBacking meansInserts for three-dimensional seams
B21C 37/15 - Making tubes of special shapeMaking the fittings
B23K 26/302 - Seam welding of three-dimensional seams of helicoidal seams
F16L 9/16 - Rigid pipes wound from sheets or strips, with or without reinforcement
B21B 1/22 - Metal rolling methods or mills for making semi-finished products of solid or profiled cross-sectionSequence of operations in milling trainsLayout of rolling-mill plant, e.g. grouping of standsSuccession of passes or of sectional pass alternations for rolling bands or sheets of indefinite length
B23P 13/02 - Making metal objects by operations essentially involving machining but not covered by a single other subclass in which only the machining operations are important
B23P 15/02 - Making specific metal objects by operations not covered by a single other subclass or a group in this subclass turbine or like blades from one piece
Devices, systems, and methods are directed to mounting an auxiliary component to a tower based at least in part on a force distribution in which a normal force is greater than a shear force exerted by the auxiliary component on a shell of the tower such that the auxiliary component may be held in place relative to the tower without penetrating the shell of the tower. Thus, as compared to mounting techniques requiring penetration of the shell of the tower, this force distribution along the shell of the tower may facilitate mounting the auxiliary component to the tower with little to no impact on cost and/or structural requirements of the tower. Further, or instead, as compared to other mounting techniques, mounting the auxiliary component based at least in part on this force distribution may reduce or eliminate the need for specialized tools, thus facilitating in-field installation of the auxiliary component.
Spiral forming devices, systems, and methods can be used to join edges of a of a stock material, in a curved configuration, along one or more joints to form tubular structures, such as conical and/or cylindrical structures (e.g., frusto-conical structures). A planar form of the stock material can be formed from a plurality planar sheets coupled to one another in an abutting relationship. By controlling relative orientation and shapes of the plurality of planar sheets forming the stock material and/or by controlling a position of a roll bender used to curve the planar form of the stock material into the curved configuration, the curved configuration of the stock material can be controlled through transitions between sheets to facilitate rolling the sheets to a desired diameter with a reduced likelihood of dimples or other errors and to facilitate fit up between adjacent sheets in the curved configuration.
B21C 37/18 - Making tubes with varying diameter in longitudinal direction conical tubes
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
E04H 12/08 - Structures made of specified materials of metal
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.
B23K 37/04 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work
F16L 23/024 - Flanged joints the flanges being connected by members tensioned axially characterised by how the flanges are joined to, or form an extension of, the pipes
F16L 23/12 - Flanged joints specially adapted for particular pipes
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
B23K 37/053 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work aligning cylindrical workClamping devices therefor
B23K 37/047 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work moving work to adjust its position between soldering, welding or cutting steps
B23K 37/00 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass
A system and a method are directed to automated techniques for fitting flanges to tubular sections used to form tubular structures (200), such as large-scale structures (200) used in industrial applications (e.g., wind towers and pipelines). As compared to manual techniques for fitting flanges to tubular sections, the system and the method 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 system and the method of the present disclosure facilitate achieving tighter dimensional tolerances. In turn, such tighter dimensional tolerances are useful for forming thinner-walled, lighter, and lower cost tubular structures. Also automated techniques for fitting flanges to tubular sections facilitate attachment of multi-piece flanges or other non- traditional flange geometries.
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
B23K 37/04 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work
B23K 37/047 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work moving work to adjust its position between soldering, welding or cutting steps
19.
SYSTEM FOR FLANGE FITTING FOR TUBULAR STRUCTURES; METHOD OF FITTING A FLANGE TO A TUBULAR SECTION
A system and a method are directed to automated techniques for fitting flanges to tubular sections used to form tubular structures (200), such as large-scale structures (200) used in industrial applications (e.g., wind towers and pipelines). As compared to manual techniques for fitting flanges to tubular sections, the system and the method 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 system and the method of the present disclosure facilitate achieving tighter dimensional tolerances. In turn, such tighter dimensional tolerances are useful for forming thinner-walled, lighter, and lower cost tubular structures. Also automated techniques for fitting flanges to tubular sections facilitate attachment of multi-piece flanges or other non- traditional flange geometries.
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
B23K 37/04 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work
B23K 37/047 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work moving work to adjust its position between soldering, welding or cutting steps
B23K 37/053 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work aligning cylindrical workClamping devices therefor
Spiral forming methods can be used to join edges of a rolled material along a spiral joint to form conical and/or cylindrical structures. Alignment of the edges of the rolled material can be controlled in a wrapping direction as the material is being joined along the spiral joint to form the structure. By controlling alignment of the edges of the material as the edges of the material are being joined, small corrections can be made over the course of forming the structure facilitating control over geometric tolerances of the resulting spiral formed structure.
Spiral forming devices, systems, and methods can be used to join edges of a of a stock material, in a curved configuration, along one or more joints to form tubular structures, such as conical and/or cylindrical structures (e.g., frusto-conical structures). A planar form of the stock material can be formed from a plurality planar sheets coupled to one another in an abutting relationship. By controlling relative orientation and shapes of the plurality of planar sheets forming the stock material and/or by controlling a position of a roll bender used to curve the planar form of the stock material into the curved configuration, the curved configuration of the stock material can be controlled through transitions between sheets to facilitate rolling the sheets to a desired diameter with a reduced likelihood of dimples or other errors and to facilitate fit up between adjacent sheets in the curved configuration.
B21C 37/18 - Making tubes with varying diameter in longitudinal direction conical tubes
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
E04H 12/08 - Structures made of specified materials of metal
22.
Control system and method for tapered structure construction
A control system for forming a tapered structure includes a sensor providing feedback for a machine for forming a tapered structure including at least three rolls having at least one bend roll and at least two guide rolls. The guide rolls may include rollette banks having a plurality of rollettes. The machine may also include an adjustment mechanism to position at least one of the rolls, where a diameter of the tapered structure being formed is controlled by relative positions of the rolls. The machine may also include a joining element to join edges of a stock of material together as it is rolled through the rolls to form the tapered structure. The control system may also include a controller to receive feedback from the sensor and to send a control signal based on the feedback to the adjustment mechanism for positioning at least one of the rolls.
Tube forming methods can be used for efficient transition in the production of tubes having varying thickness. Material used to form consecutive tubes may have the same thickness along a separation plane separating a first discrete section from a second discrete section of the material, and the first discrete section and the second discrete section may each have varying thickness in a feed direction of the material. With such a thickness profile, the first discrete section of the material may be formed into a first cylinder having varying thickness and separated from the second discrete portion as the second discrete section is formed into a second cylinder having varying thickness. In particular, the transition between the first cylinder and the second cylinder may be achieved without scrap and/or interruption, resulting in cost-savings and improvements in production throughput associated with forming tubes having varying thickness.
F16L 9/16 - Rigid pipes wound from sheets or strips, with or without reinforcement
B21C 37/12 - Making tubes or metal hoses with helically arranged seams
B21C 37/26 - Making finned or ribbed tubes by fixing strip or like material to tubes helically-ribbed tubes
B23K 9/032 - Seam weldingBacking meansInserts for three-dimensional seams
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
B21C 37/15 - Making tubes of special shapeMaking the fittings
B23K 26/302 - Seam welding of three-dimensional seams of helicoidal seams
A method for creating a tapered spiral welded conical structure where the overall shape of the cone is first graphically slit axially and unwrapped, and then a series of construction arcs and lines are created to form the edge lines of a strip that can then be wrapped (rolled) to form a tapered conical structure. The edges of the spirally wound strip can be welded together, and a very large conical structure can thus be achieved. Various construction options are presented from a constant width strip to strip made from straight segments. Equations are given for the formation of the strips to enable those skilled in the art of spiral welded tubing to practice the invention.
B21C 37/12 - Making tubes or metal hoses with helically arranged seams
E04H 12/08 - Structures made of specified materials of metal
B21C 37/18 - Making tubes with varying diameter in longitudinal direction conical tubes
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
E04H 12/34 - Arrangements for erecting or lowering towers, masts, poles, chimney stacks, or the like
Devices, systems, and methods are directed to mounting an auxiliary component to a tower based at least in part on a force distribution in which a normal force is greater than a shear force exerted by the auxiliary component on a shell of the tower such that the auxiliary component may be held in place relative to the tower without penetrating the shell of the tower. Thus, as compared to mounting techniques requiring penetration of the shell of the tower, this force distribution along the shell of the tower may facilitate mounting the auxiliary component to the tower with little to no impact on cost and/or structural requirements of the tower. Further, or instead, as compared to other mounting techniques, mounting the auxiliary component based at least in part on this force distribution may reduce or eliminate the need for specialized tools, thus facilitating in-field installation of the auxiliary component.
Tube forming methods can be used for efficient transition in the production of tubes having varying thickness. Material used to form consecutive tubes may have the same thickness along a separation plane separating a first discrete section from a second discrete section of the material, and the first discrete section and the second discrete section may each have varying thickness in a feed direction of the material. With such a thickness profile, the first discrete section of the material may be formed into a first cylinder having varying thickness and separated from the second discrete portion as the second discrete section is formed into a second cylinder having varying thickness. In particular, the transition between the first cylinder and the second cylinder may be achieved without scrap and/or interruption, resulting in cost-savings and improvements in production throughput associated with forming tubes having varying thickness.
B21C 37/12 - Making tubes or metal hoses with helically arranged seams
B21C 37/06 - Manufacture of metal sheets, rods, wire, tubes, profiles or like semi-manufactured products, not otherwise provided forManufacture of tubes of special shape of tubes or metal hosesCombined procedures for making tubes, e.g. for making multi-wall tubes
B21D 39/02 - Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by platingTube expanders of sheet metal by folding, e.g. connecting edges of a sheet to form a cylinder
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
B29C 53/78 - Winding and joining, e.g. winding spirally helically using profiled sheets or strips
E04H 12/08 - Structures made of specified materials of metal
Devices, systems, and methods are directed to formation of tubular structures, such as spirally formed structures, having spirally extending reinforcing material. In particular, tubular structures can be formed in a continuous process in which a first material is spiral formed along a first spiral and a second material is joined to the first material along a second spiral to reinforce the spirally formed first material. As compared to manual application of reinforcing material, such a continuous process can facilitate producing tubular structures at rates suitable for high- volume, commercial fabrication. Further, or instead, as compared to the use of circumferentially extending reinforcing material to support a spiral formed tube, reinforcing the spirally formed first material with a spiral of the second material may offer certain structural advantages, such as improved resistance to buckling.
Devices, systems, and methods are directed to formation of tubular structures, such as spirally formed structures, having spirally extending reinforcing material. In particular, tubular structures can be formed in a continuous process in which a first material is spiral formed along a first spiral and a second material is joined to the first material along a second spiral to reinforce the spirally formed first material. As compared to manual application of reinforcing material, such a continuous process can facilitate producing tubular structures at rates suitable for high-volume, commercial fabrication. Further, or instead, as compared to the use of circumferentially extending reinforcing material to support a spiral formed tube, reinforcing the spirally formed first material with a spiral of the second material may offer certain structural advantages, such as improved resistance to buckling.
Devices, systems, and methods are directed to mounting an auxiliary component to a tower based at least in part on a force distribution in which a normal force is greater than a shear force exerted by the auxiliary component on a shell of the tower such that the auxiliary component may be held in place relative to the tower without penetrating the shell of the tower. Thus, as compared to mounting techniques requiring penetration of the shell of the tower, this force distribution along the shell of the tower may facilitate mounting the auxiliary component to the tower with little to no impact on cost and/or structural requirements of the tower. Further, or instead, as compared to other mounting techniques, mounting the auxiliary component based at least in part on this force distribution may reduce or eliminate the need for specialized tools, thus facilitating in-field installation of the auxiliary component.
Tube forming methods can be used for efficient transition in the production of tubes having varying thickness. Material used to form consecutive tubes may have the same thickness along a separation plane separating a first discrete section from a second discrete section of the material, and the first discrete section and the second discrete section may each have varying thickness in a feed direction of the material. With such a thickness profile, the first discrete section of the material may be formed into a first cylinder having varying thickness and separated from the second discrete portion as the second discrete section is formed into a second cylinder having varying thickness. In particular, the transition between the first cylinder and the second cylinder may be achieved without scrap and/or interruption, resulting in cost-savings and improvements in production throughput associated with forming tubes having varying thickness.
B21C 37/15 - Making tubes of special shapeMaking the fittings
B21C 37/12 - Making tubes or metal hoses with helically arranged seams
B21C 37/26 - Making finned or ribbed tubes by fixing strip or like material to tubes helically-ribbed tubes
B23K 9/032 - Seam weldingBacking meansInserts for three-dimensional seams
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
Feeding stock used to form a tapered structure into a curving device such that each point on the stock undergoes rotational motion about a peak location of the tapered structure; and the stock meets a predecessor portion of stock along one or more adjacent edges.
Spiral forming devices, systems, and methods can be used to join edges of a of a stock material, in a curved configuration, along one or more joints to form tubular structures, such as conical and/or cylindrical structures (e.g., frusto-conical structures). A planar form of the stock material can be formed from a plurality planar sheets coupled to one another in an abutting relationship. By controlling relative orientation and shapes of the plurality of planar sheets forming the stock material and/or by controlling a position of a roll bender used to curve the planar form of the stock material into the curved configuration, the curved configuration of the stock material can be controlled through transitions between sheets to facilitate rolling the sheets to a desired diameter with a reduced likelihood of dimples or other errors and to facilitate fit up between adjacent sheets in the curved configuration.
B21C 37/06 - Manufacture of metal sheets, rods, wire, tubes, profiles or like semi-manufactured products, not otherwise provided forManufacture of tubes of special shape of tubes or metal hosesCombined procedures for making tubes, e.g. for making multi-wall tubes
B21C 37/08 - Making tubes with welded or soldered seams
B21C 37/083 - Supply, or operations combined with supply, of strip material
B21C 37/12 - Making tubes or metal hoses with helically arranged seams
B21C 37/14 - Making tubes from doubled flat material
B21C 37/18 - Making tubes with varying diameter in longitudinal direction conical tubes
Spiral forming devices, systems, and methods can be used to join edges of a of a stock material, in a curved configuration, along one or more joints to form tubular structures, such as conical and/or cylindrical structures (e.g., frusto-conical structures). A planar form of the stock material can be formed from a plurality planar sheets coupled to one another in an abutting relationship. By controlling relative orientation and shapes of the plurality of planar sheets forming the stock material and/or by controlling a position of a roll bender used to curve the planar form of the stock material into the curved configuration, the curved configuration of the stock material can be controlled through transitions between sheets to facilitate rolling the sheets to a desired diameter with a reduced likelihood of dimples or other errors and to facilitate fit up between adjacent sheets in the curved configuration.
B21C 37/18 - Making tubes with varying diameter in longitudinal direction conical tubes
B21C 37/06 - Manufacture of metal sheets, rods, wire, tubes, profiles or like semi-manufactured products, not otherwise provided forManufacture of tubes of special shape of tubes or metal hosesCombined procedures for making tubes, e.g. for making multi-wall tubes
B21C 37/08 - Making tubes with welded or soldered seams
B21C 37/083 - Supply, or operations combined with supply, of strip material
B21C 37/12 - Making tubes or metal hoses with helically arranged seams
B21C 37/14 - Making tubes from doubled flat material
Spiral forming devices, systems, and methods can be used to join edges of a of a stock material, in a curved configuration, along one or more joints to form tubular structures, such as conical and/or cylindrical structures (e.g., frusto-conical structures). A planar form of the stock material can be formed from a plurality planar sheets coupled to one another in an abutting relationship. By controlling relative orientation and shapes of the plurality of planar sheets forming the stock material and/or by controlling a position of a roll bender used to curve the planar form of the stock material into the curved configuration, the curved configuration of the stock material can be controlled through transitions between sheets to facilitate rolling the sheets to a desired diameter with a reduced likelihood of dimples or other errors and to facilitate fit up between adjacent sheets in the curved configuration.
B21C 37/18 - Making tubes with varying diameter in longitudinal direction conical tubes
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
E04H 12/08 - Structures made of specified materials of metal
A method for creating a tapered spiral welded conical structure where the overall shape of the cone is first graphically slit axially and unwrapped, and then a series of construction arcs and lines are created to form the edge lines of a strip that can then be wrapped (rolled) to form a tapered conical structure. The edges of the spirally wound strip can be welded together, and a very large conical structure can thus be achieved. Various construction options are presented from a constant width strip to strip made from straight segments. Equations are given for the formation of the strips to enable those skilled in the art of spiral welded tubing to practice the invention.
B21C 37/12 - Making tubes or metal hoses with helically arranged seams
E04H 12/08 - Structures made of specified materials of metal
B21C 37/18 - Making tubes with varying diameter in longitudinal direction conical tubes
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
E04H 12/34 - Arrangements for erecting or lowering towers, masts, poles, chimney stacks, or the like
Spiral forming methods can be used to join edges of a rolled material along a spiral joint to form conical and/or cylindrical structures. Alignment of the edges of the rolled material can be controlled in a wrapping direction as the material is being joined along the spiral joint to form the structure. By controlling alignment of the edges of the material as the edges of the material are being joined, small corrections can be made over the course of forming the structure facilitating control over geometric tolerances of the resulting spiral formed structure.
B21B 38/10 - Methods or devices for measuring specially adapted for metal-rolling mills, e.g. position detection, inspection of the product for measuring roll-gap, e.g. pass indicators
B21B 37/00 - Control devices or methods specially adapted for metal-rolling mills or the work produced thereby
B21B 37/16 - Control of thickness, width, diameter or other transverse dimensions
B21B 37/38 - Control of flatness or profile during rolling of strip, sheets or plates using roll bending
B21B 38/00 - Methods or devices for measuring specially adapted for metal-rolling mills, e.g. position detection, inspection of the product
B21B 38/04 - Methods or devices for measuring specially adapted for metal-rolling mills, e.g. position detection, inspection of the product for measuring thickness, width, diameter or other transverse dimensions of the product
Spiral forming methods can be used to join edges of a rolled material along a spiral joint to form conical and/or cylindrical structures. Alignment of the edges of the rolled material can be controlled in a wrapping direction as the material is being joined along the spiral joint to form the structure. By controlling alignment of the edges of the material as the edges of the material are being joined, small corrections can be made over the course of forming the structure facilitating control over geometric tolerances of the resulting spiral formed structure.
Feeding stock used to form a tapered structure into a curving device such that each point on the stock undergoes rotational motion about a peak location of the tapered structure; and the stock meets a predecessor portion of stock along one or more adjacent edges.
A control system for forming a tapered structure includes a sensor providing feedback for a machine for forming a tapered structure including at least three rolls having at least one bend roll and at least two guide rolls. The guide rolls may include rollette banks having a plurality of rollettes. The machine may also include an adjustment mechanism to position at least one of the rolls, where a diameter of the tapered structure being formed is controlled by relative positions of the rolls. The machine may also include a joining element to join edges of a stock of material together as it is rolled through the rolls to form the tapered structure. The control system may also include a controller to receive feedback from the sensor and to send a control signal based on the feedback to the adjustment mechanism for positioning at least one of the rolls.
B23K 37/053 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work aligning cylindrical workClamping devices therefor
40.
Control system and method for tapered structure construction
A control system for forming a tapered structure includes a sensor providing feedback for a machine for forming a tapered structure including at least three rolls having at least one bend roll and at least two guide rolls. The guide rolls may include rollette banks having a plurality of rollettes. The machine may also include an adjustment mechanism to position at least one of the rolls, where a diameter of the tapered structure being formed is controlled by relative positions of the rolls. The machine may also include a joining element to join edges of a stock of material together as it is rolled through the rolls to form the tapered structure. The control system may also include a controller to receive feedback from the sensor and to send a control signal based on the feedback to the adjustment mechanism for positioning at least one of the rolls.
B21C 37/12 - Making tubes or metal hoses with helically arranged seams
B21C 37/18 - Making tubes with varying diameter in longitudinal direction conical tubes
B23K 9/032 - Seam weldingBacking meansInserts for three-dimensional seams
B23K 37/053 - Auxiliary devices or processes, not specially adapted for a procedure covered by only one of the other main groups of this subclass for holding or positioning work aligning cylindrical workClamping devices therefor
41.
CONTROL SYSTEM AND METHOD FOR TAPERED STRUCTURE CONSTRUCTION
A control system for forming a tapered structure includes a sensor providing feedback for a machine for forming a tapered structure including at least three rolls having at least one bend roll and at least two guide rolls. The guide rolls may include rollette banks having a plurality of rollettes. The machine may also include an adjustment mechanism to position at least one of the rolls, where a diameter of the tapered structure being formed is controlled by relative positions of the rolls. The machine may also include a joining element to join edges of a stock of material together as it is rolled through the rolls to form the tapered structure. The control system may also include a controller to receive feedback from the sensor and to send a control signal based on the feedback to the adjustment mechanism for positioning at least one of the rolls.
B21B 39/00 - Arrangements for moving, supporting, or positioning work, or controlling its movement, combined with or arranged in, or specially adapted for use in connection with, metal-rolling mills
A method for creating a tapered spiral welded conical structure where the overall shape of the cone is first graphically slit axially and unwrapped, and then a series of construction arcs and lines are created to form the edge lines of a strip that can then be wrapped (rolled) to form a tapered conical structure. The edges of the spirally wound strip can be welded together, and a very large conical structure can thus be achieved. Various construction options are presented from a constant width strip to strip made from straight segments. Equations are given for the formation of the strips to enable those skilled in the art of spiral welded tubing to practice the invention.
B21C 37/12 - Making tubes or metal hoses with helically arranged seams
B21C 37/18 - Making tubes with varying diameter in longitudinal direction conical tubes
B23K 31/02 - Processes relevant to this subclass, specially adapted for particular articles or purposes, but not covered by any single one of main groups relating to soldering or welding
E04H 12/08 - Structures made of specified materials of metal
Feeding stock used to form a tapered structure into a curving device such that each point on the stock undergoes rotational motion about a peak location of the tapered structure; and the stock meets a predecessor portion of stock along one or more adjacent edges.
Feeding stock used to form a tapered structure into a curving device such that each point on the stock undergoes rotational motion about a peak location of the tapered structure; and the stock meets a predecessor portion of stock along one or more adjacent edges.
A device for fabricating a frusto-conical structure is provided. The device has a curving device controllable to impart curvature to a planar form of a stock, and a feed system. A control system delivers control signals to the curving device and the feed system to form a planar form of the stock into the frusto-conical structure. The control system differentially drives an outer drive wheel pair of rollers of the feed system relative to an inner drive wheel pair of rollers of the feed system to impart, to a portion of the stock that has not yet been deformed, a substantially rotational motion in a plane of the portion of the stock about a virtual peak of the frusto-conical structure such that each location on the portion of the stock that has not yet been deformed maintains a constant distance from the virtual peak throughout feeding.
Feeding stock used to form a tapered structure into a curving device such that each point on the stock undergoes rotational motion about a peak location of the tapered structure; and the stock meets a predecessor portion of stock along one or more adjacent edges.
A method for creating a tapered spiral welded conical structure where the overall shape of the cone is first graphically slit axially and unwrapped, and then a series of construction arcs and lines are created to form the edge lines of a strip that can then be wrapped (rolled) to form a tapered conical structure. The edges of the spirally wound strip can be welded together, and a very large conical structure can thus be achieved. Various construction options are presented from a constant width strip to strip made from straight segments. Equations are given for the formation of the strips to enable those skilled in the art of spiral welded tubing to practice the invention.
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