System and Method for Separating a Tubular Component

Abstract

A system and a method for separating a tubular component is disclosed, which for constructing a supporting structure, having a longitudinal pipe with pipe ends which are open on both sides. The system has a mobile transport module comprising a receiving platform having a pipe clamping device for clamping variable pipe diameters which receives and mounts the tubular component so that a first pipe end of the component, having a vertical longitudinal axis which detachably and securely engages the pipe clamping device. The invention further relates to a separating arrangement mounted on a supporting structure that it is deflectable at least vertically, to provide secure joining to the pipe end of a tubular component that faces away from the first pipe end. The tubular component is seated on the transport module and vertically securely engages the pipe clamping device.

Claims

1.-16. (canceled)

17. A system for separating a tubular component for constructing a supporting structure, including a longitudinal pipe with pipe ends that are open on both sides, comprising: a mobile transport module including a receiving platform including a pipe clamping device adaptable to different pipe diameters, which receives and mounts the tubular component so that a first pipe end of the tubular component, which is oriented vertically, can be positioned in a detachable, engagement with the pipe clamping device; and a separating arrangement which is mounted on a supporting structure that can be raised and lowered, include a fastening arrangement for detachable and secure joint to the second pipe end, opposite the first pipe end, of a tubular component that is seated vertically on the mobile transport module and engaged with the pipe clamping device, and which includes at least one manipulator unit which is attachable to the fastening arrangement with a freely positionable manipulator end to which a separating tool is attached, the tool being guidable along a controlled trajectory relative to the tubular component radially outside of the tubular component.

18. The system according to claim 17, wherein the pipe clamping device comprises at least two clamping blocks moveably mounted and lockable along the receiving platform so that the clamping blocks on at least one of inside and outside of a vertically oriented tubular component supported on the receiving platform, are distributed evenly along either the inner wall or outer wall thereof, and positionable into engagement with the tubular component for exerting clamping forces at least one of directed radially outwardly and radially inwardly against at least one of the inner and the outer wall.

19. The system according to claim 18, wherein the clamping blocks each include vertically adjustable bracing structure so that each bracing structure of each individual clamping block can engage a region along a front rim of a lower pipe end for matching with the vertically oriented tubular component.

20. The system according to claim 19, wherein each bracing structure includes a fork-shaped receiving structure.

21. The system according to claims 17, comprising: a vertically displaceable bracing unit mounted on the receiving platform, on which a separating or a welding assembly is supported with a joint between the fastening arrangement and the tubular component.

22. The system according to claims 17, wherein the mobile transport module is one of a low-loader transport vehicle, a mobile loading unit, load-bearing, bottom supporting vehicle, and a device or a base platform which is operatable in a production plane.

23. The system according to claims 17, wherein the fastening arrangement of the separating arrangement comprises a clamping module which is insertable at least partially in an axial front face of the upper end of the tubular component that is positionable vertically on the receiving module, is releasable, and provides attachment to a pipe inner wall which is part of the tubular component, and has a carrier ring module mounted rotatably with the clamping module, which in a joined state of the clamping module protrudes axially beyond the upper end of the tubular component and is in operative connection with a servomotor for driving the carrier ring module rotationally about the pipe longitudinal axis such that the carrier ring module is mounted to be rotatable around the pipe longitudinal axis.

24. The system according to claim 22, comprising: at least one linear supporting structure is attached to the carrier ring module, which is mounted to be bidirectionally deflectable parallel to a longitudinal axis of the tubular component and is positionable vertically on the receiving module by an actuator.

25. The system according to claim 24, wherein the activator is an at least 3-axis open kinematic chain formed as a vertical articulated-arm robot mounted on one end of the supporting structure.

26. The system according to claim 24, comprising a supply module on which is mounted at least one of: a control unit, an electrical power supply unit, at least one reservoir for materials required for the separating process comprising at least process gas, the at least one component is connected to the separating tool via a connecting line, the supply module is rotatably mounted for imparting a rotary motion around the pipe longitudinal axis simultaneously with movement of the separating tool which enables rotations of the cutting tool about the pipe longitudinal axis and the supply module is articulated or a supporting structure separated from the cutting arrangement to be positionable at least along one plane, or the supply module is connected to the carrier ring module.

27. The system according to claim 17, comprising: at least one contactless measurement sensor which is at least one of located on the separating arrangement and on the mobile transport module, so that a contour of at least one of a separating process and tubular component to be separated can be recorded and the separating process is monitorable and overrideable.

28. A method for separating a tubular component for constructing a supporting structure, including a longitudinal pipe having open pipe ends on sides, with a separating tool being guided by a specification of a separating curve along an outer wall of the tubular component for cutting the component apart, comprising method steps: positioning the tubular component relative to a vertically oriented longitudinal pipe on a mobile transport module; positioning the tubular component relative to a separating arrangement which is mounted on a supporting structure to be at least raised and lowered vertically; depositing and securing the separating arrangement on an upper pipe end of the tubular component seated vertically on the transport module; separating the tubular component along the separating curve to obtain component parts that are disconnected from each other, to form lower and an upper component parts, by use of the separating arrangement; lifting and transporting the upper component part by use of a separating welding assembly; and transporting the lower component part which is supported on the mobile transport module.

29. The method according to claim 27, comprising: bracing the separating arrangement during bracing the separating arrangement against the mobile transport module separately from the tubular component.

30. The method according to claim 28, comprising: performing the separation by using at least one separating tool, located radially outside the tubular component and which is guided along the separating curve around the tubular component.

31. The method according to claim 28, comprising: capturing the tubular component to be separated without contact at least before and during the separation process; and monitoring the separating process and making corrections in situ.

32. A method of use of the system according to claim 17 for reworking a tubular component in a grinding process, comprising: replacing a separating tool attached to an end of a manipulator end with a grinding tool and which the separating arrangement is seated on the tubular component machining a radially outer shell surface of the tubular component.

Description

BRIEF SUMMARY OF THE DRAWINGS

[0033] In the following text, the invention will be explained without limitation of the general inventive thought for exemplary purpose using embodiments thereof and with reference to the drawing. In the drawing:

[0034] FIG. 1 shows a general overview of the system according to the invention;

[0035] FIG. 2 shows a mobile transport system;

[0036] FIG. 3 is a detailed representation illustrating the separating welding assembly attached to the tubular component in detailed general view;

[0037] FIG. 4 shows the overall system; and

[0038] FIG. 5a-d shows a sequence of images representing the performance of a separating welding process on a tubular component.

DETAILED DESCRIPTION OF THE INVENTION

[0039] FIG. 1 is a perspective showing a diagrammatic view of the system according to the invention for separating a tubular component 1, which in

[0040] FIG. 1 is a straight steel cylinder supported on a horizontally oriented receiving platform 2 of a mobile transport module 3, which travels freely along a production plane E. The mobile transport module 3 illustrated in FIG. 1 is preferably a low-loader transport vehicle. Alternatively, it is also possible to implement the mobile transport module 3 in the form of other load-bearing vehicles with carrier function or devices that are operable in the production plane.

[0041] The system according to the invention also provides a separating arrangement 4 which is separate for the mobile transport module 3 and also separate from the tubular component 1. The separating arrangement is supported on a supporting structure 6 such that it can be at least raised and lowered vertically by means of a suspension assembly 5, preferably via cable winches for the purpose of processing preparation and setup. The considerably simplified suspension assembly 5 represented in FIG. 1 is to be understood to represent any conceivable form of mechanical connection between the separating module 4 and the load-bearing supporting structure 6. The supporting structure 6 may be embodied as a lattice framework which is braced intrinsically stably on production plane E. Equally, it is also possible to support the weight of the separating arrangement 4 with a stationary or mobile crane system, which also enables vertical movements, preferably a spatially free positioning of the separating arrangement 4.

[0042] Given the capability of mobile positioning of the tubular component 1 along the production plane E by using the transport module 3 and the at least vertically variably positionable separating arrangement 4, it is possible to transfer the tubular component 1 and the separating arrangement 4 to a vertically overlapping position, in which the separating arrangement 4 is lowered vertically in the direction of the upper, open pipe end 7 of the vertically oriented tubular component 1.

[0043] The separating arrangement 4 is equipped with a fastening arrangement 8 which is arranged below a support platen assembly 9 of the separating arrangement 4 and opens into the interior of the tubular component 1, while the support platen assembly 9 is supported on the circular upper pipe end 7 which terminates at the front face.

[0044] The separating arrangement 4 is connected detachably and securely to the inner wall of the tubular component 1 by use of a form-fitting joint via the fastening arrangement 8.

[0045] Two linear arrangements 10 are mounted along the peripheral border of the support platen assembly 9, and are mounted so as to be deflectable vertically downwards and upwards when the separating arrangement 4 is joined to the tubular component 1. A manipulator unit 11 in the form of an at least 3-axis kinematic chain, but preferably in the form of a six-axis open kinematic chain, like a vertical articulated-arm robot for example, is mounted on the bottom end of each linear unit 10, and a separating tool 12 is provided on the manipulator end thereof.

[0046] The linear units 10 together with the manipulator unit 11 are attached to each other and the separating tool 12 is mounted to be rotatable about the support platen assembly 9 and thus also rotatable about the outer circumference of the tubular component 1.

[0047] By providing two separating tools 12, the duration of a separating process can be halved, which is notably advantageous particularly in cases in which tubular components 1 with large wall thicknesses are to be separated.

[0048] In order to supply a process gas to each separating tool 12, the embodiment illustrated in FIG. 1 provides at least one supply module 13, which contains all of the components relating to the cutting process, such as a control unit, an electrical power supply unit and at least one reservoir for materials required for the separating welding process, comprising at least the process gas.

[0049] FIG. 2 illustrates an embodiment of the construction of a mobile transport module 3. The mobile base is preferably supplied in the form of a low-loader vehicle having a flat, horizontal receiving platform 2, on which a pipe clamping device 14 is mounted, which in the embodiment of FIG. 4 comprises four clamping blocks 15. Each of the individual clamping blocks 15 is movable along a linear axis 15 and also lockable relative to the receiving platform 2. In order to fasten a tubular component 1 detachably and securely, the clamping blocks 15 are pressed flush against the inner wall of the tubular component 1 under the effect of a pressing force and braced against the wall. In order to deflect the individual clamping blocks 15 along their displacement axes 15 and generate a clamping force enabled thereby to act on the tubular component 1 and secure it on the mobile transport module 3, the individual clamping blocks 15 are mounted such that they are deflectable by electromotor, pneumatic or hydraulic means.

[0050] In addition, each individual clamping block 15 has a vertically deflectable bracing structure 16, which serves to surround and receive the pipe rim structure locally at the face thereof preferably in the manner of a fork.

[0051] Finally, the mobile transport module 3 provides a vertically displaceable bracing unit 17 with a receiving platform 17 which serves to receive and support the separating cutting device 4. In this way, the receiving platform 17 whose height can be adjusted individually prevents the separating cutting arrangement from sinking during and after a desired cutting contour has been created along the circumferential border of the tubular components. Preferably, the bracing unit 17 provides a spindle-driven, telescopic support mechanism for vertical height adjustment of the receiving platform 17.

[0052] FIG. 3 illustrates a schematic representation of the separating cutting arrangement 4 joined securely to a tubular component 1. For reliable, detachably secure support of the separating cutting arrangement 4 solely at the upper end of the tubular component 1, the fastening arrangement 8 protruding into the interior of the pipe includes motor-driven clamping jaws 8 which may be pressed radially against the inner wall of the tubular component 1, which fix the fastening arrangement 8 and therewith also the entire separating cutting arrangement 4 centrally to the tubular component 1. In all, the fastening arrangement 8 has three, four or more clamping jaws 8 of such kind. Rollers 8 mounted so as to be freely rotatable on the lower end of the fastening arrangement 8 help to enable the fastening arrangement 8 to be introduced into the upper pipe end of the tubular component 1 more easily and without causing damage.

[0053] The support platen assembly 9 provides a lower support platen 9 which enters into direct frontal contact with the upper end of the tubular component 1. A carrier ring module 9 is provided that is rotatable with respect to the lower support platen 9 and is driven by a motor about the axis of rotation D. The linear units 10 are each connected fixedly to the carrier ring module 9 via a holding device 18 and are displaceable by motor along the linear axis L, which corresponds to the vertical axis when the separating arrangement 4 is in the connected state with the vertically oriented tubular component 1. The manipulator unit 11 is attached to the lower end of the linear unit 10, and the separating tool 12 is attached to the manipulator end thereof so as to be spatially freely positionable.

[0054] In the embodiment shown in FIG. 3, corresponding supply modules 13 are provided at both the upper and the lower ends of the linear unit 10 to enable the separating operation to be carried out in a controlled, power-assisted manner.

[0055] In the representation according to FIG. 4, the state is illustrated in which the separating welding assembly 4 is joined firmly to the upper pipe end 7 of the tubular component 1. In the case shown in FIG. 4, the separating arrangement 4 is attached via a connecting means 5 to a carrier module 19, on which essential supply components for the separating process are accommodated, as will be explained subsequently. The carrier module 19 is connected to the supporting structure 6 via the suspension assembly 5.

[0056] The suspension assembly 5 and the connecting means 5 ensure that the separating device 4 may be positioned without spatial limitation along the orthogonally oriented spatial directions x, y, z marked in FIG. 4. The suspension assembly 5 is advantageously connected to the supporting structure 6 via a rail suspension assembly for guiding and/or positioning the module carrier 19 and the separating arrangement 4 which is coupled therewith via the connecting means 5, and enables deflection of the suspension assembly 5 along the x- and y-directions indicated. Telescopic mechanisms, cylinder stroke units, spindle drives, control wire drives to name just a few are suitable arrangements for creating the connecting means 5 for the spatial positioning of the separating arrangement 4 along the vertical z-axis.

[0057] All of the logistical components and supply modules 13 necessary for the separating process are accommodated on the module carrier 19. These comprise one control and power unit for each separating tool 12 and a reservoir for process gas. The supply of energy and transmission of corresponding control signals to the supply modules 13 located on the module carrier 19 preferably takes place via an external cable feed 20, which is coupled via a slipring coupling (not shown) disposed centrally in the area of the module carrier 19. Depending on requirements, a further external feed line 21 is provided, via which process gas is supplied. The connection of the process gas to the supply modules 13 accommodated on the module carrier 19 is also assured via a fluid-tight slipring coupling (not shown). This enables external energy source and also gas reservoirs, in the form of gas bottles for example to be kept in reserve in readily accessible locations in the area of the production plane E and used accordingly.

[0058] Finally, flexible connecting lines 23 are provided between the supply modules 13 and corresponding connecting units 22 at the upper ends of the linear units 10 and serve to supply the separating tools 12 with energy as well as the process gas needed for the separating process.

[0059] Because of the rotatable mounting of the separating tools 12 about the longitudinal axis of the tubular component 1 which is enabled by the carrier ring module 9, it is necessary to rotate the supply modules 13 arranged on the module carrier 19 about the pipe longitudinal axis in the same mode as the rotating motion of the separating tools 12, in order to prevent the connecting lines 23 from becoming twisted and suffering damage.

[0060] In all other aspects and except for the special design of the separating tool 12, the separating arrangement 4 described above is explained comprehensively in a patent application PCT/EP2016/055623 and DE 10 2015 206 044.6 which is unpublished at the time of this application. The welding assembly described in the two abovementioned applications is used to join two pipe sockets with the aid of a welding tool. With the exception of the welding tool described therein, the constructive design is otherwise identical to the separating apparatus disclosed as part of the present application. In this context, reference is made to the disclosure contents of the two abovementioned documents in their entirety.

[0061] FIGS. 5a to d describe the process of separating a tubular component with the aid of the system according to the invention in the form of an image sequence.

[0062] The process state shown in FIG. 5a, in which the tubular component 1 is already releasably and securely mounted in vertical orientation on the mobile transport module 3 and the separating arrangement 4 is seated on the upper pipe end of the tubular component and is joined in spatially defined manner to the tubular component 1 by use of the fastening arrangement is preceding by the step of loading the mobile transport module 3 with the tubular component 1. For this purpose, the tubular component 1 is positioned opposite the pipe clamping device on the receiving platform 2 of the transport module 3 with the a crane system (not shown) for example and lowered. As was described previously, the tubular component 1 is fixed securely on the mobile transport module by use the pipe clamping device. It is also necessary to position the mobile transport module 3 relative to the separating arrangement 4. It is further important to center the separating arrangement 4 in suitable manner coaxially with the tubular component 1 seated on the mobile transport module 3 and to lower it accordingly.

[0063] The separating arrangement 4 is lowered onto the upper pipe end with the suspension assembly (not illustrated in FIG. 5) for example with cable winches, wherein the separating welding assembly 4 bears in a supporting manner on the receiving platform 17 described with reference to FIG. 2. For purposes of locking and fixing the separating welding assembly 4 in place relative to the tubular component 1, the clamping jaws 8 described with reference to FIG. 3 are moved radially outwards.

[0064] After the separating arrangement 4 has been secured correctly on the tubular component 1, the separating process is performed, in which the separating tools 12 are displaced around the circumference of the outer shell surface of the tubular component 1 along a predetermined separation trajectory 24, as also shown as the dashed line in FIG. 4. Depending on the complexity of the trajectory or the contour to be cut, the separating tools 12 may have to pass over the separation trajectory 24 several times.

[0065] Upon completion of the separating process, the separating arrangement 4 and the upper component part 1o are raised by the suspension assembly. The lower component part 1u remains on the mobile transport module 3 and is transported away as appropriate, and may be returned for reuse. See FIG. 5b in this regard.

[0066] FIG. 5c shows the lowering of the upper component part 1o, whose lower pipe end corresponds to the predetermined separation trajectory and thus has a front rim contour that differs from the original circular shape. The vertically adjustable bracing structures 16 are individually deflected vertically to match the front rim contour, so that the lower front rim of the upper component part 1o fits into the fork-like bracing structures 16 locally to guarantee a stable vertical support of the upper component parts 1o.

[0067] In the sequence step illustrated in FIG. 5d, the fastening arrangement of the separating arrangement 4 is released and detached from the upper pipe end 7. After the requisite vertical separation has been reached between the separating arrangement 4 and the tubular component 1o, the component 1o is transported away individually by the mobile transport module 3.

[0068] With the system for separating a tubular component according to the invention it is possible to carry out any cutting tasks to size on tubular components with any diameter and any initial length. In particular, it is possible to carry out contour cuts and prepare for weld seams on pipes and/or pipe sockets that are to be processed further to make pipe joints.

[0069] Through the use of a mobile transport module in conjunction with the spatially positionable separating arrangement, a compact, mobile complete system is created which may be set up at any production location and put into operation there with little effort. It is entirely conceivable that the system equipment may be operated at the construction site. It is also possible to use the system for the separating process explained in the preceding text to join two tubular components by corresponding replacement of the separating tool with a welding tool and arrangement of further linear units 10 in combination with manipulators 11 and a welding tool on the carrier ring module 9.

[0070] It is also possible to create a local hole in the shell surface of the base tube by corresponding specification of the separation trajectory within a base tube seated vertically on the mobile transport module. For this purpose, however, it is important to support the segment that is separated from the base tube with an additional, suitably constructed holding device to avoid damaging the cut contour on the base tube. Such a holding device should preferably provided inside the base tube in the region of the vertically displaceable bracing unit 17.

[0071] In a further preferred embodiment, measuring instruments are attached both to the separating arrangement and the transport module, and may be used for capturing the separation trajectory in advance and optimizing the adjustment of the contour of the tubular component to be separated during the separation process. The quality of separation and the dimensional accuracy of the separation trajectory may also be inspected. To this end, preferably contactless sensors are attached preferably to the ends of the manipulator units 10 and/or in the region of the pipe clamping device 14. This in turn enables the separating process to be monitored online, so that necessary corrections can be made in situ.

[0072] The measuring instruments for contactless capture of the tubular component in advance of the actual separating process serve mainly to deliver a precise determination of the geometry of the component itself. Accordingly, it often occurs that pipes with a pipe cross section that is not circular, for example an elliptical cross section, have to be connected in the joining process. For this purpose, it is important to design the joint contour of such pipes accordingly. The cross sectional geometries deviate from an ideal dimension not only but most frequently in the cross sections of elliptical pipe types, so that a cutting contour is created during the separating process with the specification of a numeric standard trajectory along which the separating tool is deflected, and this subsequently results in unacceptable gap size deviations when the pipes are joined later. In order to counteract the effects of such gap size deviations, the pipe segment to be processed is measured extremely precisely before the separation operation. This applies both for the base tube in shell of which a given cutout is to be created, and for a pipe socket, the pipe end must have a joint contour that is adapted exactly to the circumferential contour of the cutout in the base tube, which is specified by the separation trajectory.

[0073] The determination of the exact separation trajectory is therefore carried out on the basis of the currently measured pipe geometry, captured in each case with the measurement instrument.

LIST OF REFERENCE SIGNS

[0074] 1 Tubular component [0075] 2 Receiving platform [0076] 3 Mobile transport module [0077] 4 Separating arrangement [0078] 5 Suspension assembly [0079] 5 Connecting means [0080] 6 Supporting structure [0081] 7 Upper pipe end [0082] 8 Fastening arrangement [0083] 8 Clamping jaws [0084] 8 Rollers [0085] 9 Support platen assembly [0086] 9 Lower support platen [0087] 9 Carrier ring module [0088] 10 Linear unit [0089] 11 Manipulator [0090] 12 Separating tool [0091] 13 Supply module [0092] 14 Pipe clamping device [0093] 15 Clamping block [0094] 15 Linear axis [0095] 16 Vertically adjustable bracing structure [0096] 17 Vertically displaceable bracing unit [0097] 17 Receiving platform [0098] 18 Holding device [0099] 19 Module carrier [0100] 20 Cable feed [0101] 21 Process gas feed [0102] 22 Connecting unit [0103] 23 Connecting lines [0104] 24 Separation trajectory [0105] E Production plane, floor [0106] D Axis of rotation [0107] x,y,z Orthogonally oriented spatial axes [0108] L Linear axis