A PIPE FORMING ASSEMBLY AND METHOD OF USE

Abstract

A pipe forming assembly and method of use is provided for forming a continuous length of pipe. In particular, the present invention concerns a pipe forming assembly including: a former; at least one applicator for applying material about the former, the at least one applicator being movable relative to the former while applying material to form the pipe; and a carriage for conveying the former and the at least one applicator along a surface for forming a continuous length of pipe.

Claims

1. A pipe forming assembly for forming a continuous length of pipe including: a former; at least two winding apparatuses for winding material about the former to form the pipe; and a carriage for carrying the former and the at least two winding apparatuses along a surface while winding the material about the former for forming the continuous length of pipe, wherein the at least two winding apparatuses are each moveable at least partially along a length of the former independently of the carriage while winding the material about the former.

2. The pipe forming assembly of claim 1, wherein the at least two winding apparatuses are configured to rotate in the same direction about the former.

3. The pipe forming assembly of claim 1, wherein the at least two winding apparatuses are configured to rotate in opposite directions about the former.

4. The pipe forming assembly of claim 1, wherein the material is a fibrous material that solidifies once impregnated with a thermosetting composition.

5. The pipe forming assembly of claim 4, wherein the material is a triaxial or quadraxial fibrous material.

6. The pipe forming assembly of claim 4, wherein the material is pre-impregnated with the thermosetting composition.

7. The pipe forming assembly of claim 1, wherein each winding apparatus includes a plurality of rollers and a roller support for supporting the plurality of rollers and orbiting the plurality of rollers about the former.

8. The pipe forming assembly of claim 7, wherein the roller support is mechanically driven about the former.

9. The pipe forming assembly of claim 7, wherein each roller of the plurality of rollers is a feed roller configured to independently wind the material about the former under tension.

10. The pipe forming assembly of claim 7, wherein each roller of the plurality of roller is releasably coupled to the roller support.

11. The pipe forming assembly of claim 7, wherein an angle of each roller of the plurality of rollers is adjustable to achieve a desired wrap angle.

12. The assembly of claim 7, further including a loading arm for replacing a roller on the roller support when it is exhausted of material with a replacement roller.

13. The assembly of claim 1, wherein the former has an adjustable circumference to thereby assist in forming pipe of differing diameters and to at least partially assist in dissociating the former from a portion of pipe once cured.

14. The assembly of claim 1, wherein the former is supported on the carriage by one or more former supports.

15. The assembly of claim 14, wherein each former support is releasably connectable to the former.

16. The assembly of claim 1, wherein the carriage includes rail and a base of each winding apparatus includes one or more wheels or rollers for moving along the rail and thereby moving the winding apparatus along the carriage relative to the former.

17. The assembly of claim 1, wherein the carriage includes one or more racks and a base of each winding apparatus includes one or more pinions for moving along the racks and thereby moving the winding apparatus along the carriage relative to the former.

18. The assembly of claim 1, wherein each winding apparatus further includes at least one clamp for temporarily clamping the winding apparatus to the pipe formed about the former to at least partially assist in dissociating and/or removing the pipe from the former.

19. A pipe forming assembly including at least two of the pipe forming assembly of claim 1 arranged in series, each pipe forming assembly being configured to wind material about the former.

20. A method of forming a continuous length of pipe, said method including: winding material with at least two winding apparatuses about a former and moving the at least two winding apparatuses at least partially along a length of the former while winding the material about the former to form the pipe; and moving the at least two winding apparatuses and the former along a surface while winding the material about the former to form the continuous length of pipe.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0115] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

[0116] FIG. 1 is an illustration showing a side view of a pipe forming assembly according to an embodiment of the present invention;

[0117] FIG. 2 is an illustration showing an end view of the pipe forming assembly shown in FIG. 1

[0118] FIG. 3 is an illustration showing a side view of a pipe forming assembly according to another embodiment of the present invention;

[0119] FIG. 4 is an illustration of a pipe forming assembly according to another embodiment of the present invention in which the pipe forming assembly is capable of transitioning between horizontal and vertical operating positions; and

[0120] FIG. 5 is an illustration of part of the pipe forming assembly shown in FIG. 4 in a vertical operating position.

DETAILED DESCRIPTION

[0121] FIG. 1 shows a pipe forming assembly (100) according to an embodiment of the present invention. The pipe forming assembly (100) includes a former (110) and two winding apparatuses (120; i.e., applicators) for winding material about the former (110) to form the pipe. The winding apparatuses (120) are moveable relative to the former (110) while winding material to form the pipe. The assembly (100) further includes a carriage (130) for carrying the former (110) and the winding apparatuses (120) along a surface when forming a continuous length of pipe with the winding apparatuses (120).

[0122] The material is a fibrous material, such as, e.g., glass fibre, that has been pre-impregnated with resin (i.e., a thermosetting composition) such that it solidifies to form pipe once wound about the former (110) and allowed to cure.

[0123] Referring to FIG. 1, each winding apparatus (120) includes a frame (122; i.e., a roller support) for supporting rollers (140) and orbiting the rollers (140) about the former (110). The frame (122) includes opposed end frame members (124) joined together by one or more cross frame members (128). The end frame members (124) encircle the former (110) and are configured to rotate about the former (110). The rollers (140) extend between the end frame members (124). In use, each roller (140) is configured to wind material about the former (110) as the frame (122) rotates about the former (110) causing the rollers (140) to orbit the former (110). The frame (122) is mechanically driven to rotate about the former (110) and can rotate about the former (110) in either a clockwise or anti-clockwise direction.

[0124] The rollers (140) are arranged in the frame (122) at an adjustable angle relative to the former (110). The angle of the rollers (140) relative to the former (110) being mechanically adjustable even while the rollers (140) orbit the former (110).

[0125] Each roller (140) is a feed roller containing pre-impregnated material to be wound about the former (110). The rollers (140) are releasably coupled to the frame (122) to allow each roller (140) to be replaced once exhausted of material. The assembly further includes two loading arms (160) on opposed sides of each winding apparatus (120) for replacing the rollers (140) as they are exhausted of material. The loading arms (160) will be described in detail below with reference to FIG. 2.

[0126] The former (110), about which the material is wound to form the pipe, has a circular cross-section and an adjustable circumference to allow pipe of differing diameters to be formed, and to assist in separating the former (110) from freshly formed pipe. To adjust the circumference, the former (110) includes segment having a triangular cross-section that is moveable in a lateral direction relative to a remainder of the former (110). In use, movement of the segment inwards relative to the remainder of the former (110) decreases the circumference. Conversely, movement of the segment outwards relative to the remainder of the former (110) increases the circumference.

[0127] As shown, the carriage (130) includes a platform (132) upon which the former (110) and the winding apparatuses (120) rest and along which the apparatuses (120) move while winding material about the former (110). The carriage (130) includes tracks (134) for propelling the assembly (110) along a surface and a self-levelling suspension system (136) located between the platform (132) and the tracks (134) to assist in stabilizing the assembly (100) as it moves along a surface, particularly a rough or uneven surface.

[0128] The former (110) is supported on the carriage (130) by former supports (190) located at either end of the carriage (130).

[0129] The winding apparatuses (120) move along the carriage (130) relative to the former (110) by way of a rack and pinion system. The carriage (130) includes one or more racks of the rack and pinion system located on an upper surface of the carriage (130) and extending longitudinally along a length of the carriage (130) atop the platform (132) of the carriage (130). The base of the frame (122) of each winding apparatus (120) includes corresponding pinions of the rack and pinion system, each pinion configured to engage with the racks for moving the apparatus (120) relative to the carriage (130) and the former (110). The pinions are mechanically driven to move the apparatuses (120) along the carriage (130) relative to the former (110).

[0130] Each winding apparatus (120) further includes a mechanical clamp (170) for temporarily clamping the apparatus (120) to recently formed pipe to assist in removing the pipe from the former (110).

[0131] A microwave, ultraviolet (UV) light or infrared emitting unit (i.e., the curing unit) is located within the former (110). The microwave, UV light or infrared emitting unit cures freshly wound material about the former (110) hardening the material to form pipe.

[0132] Referring to FIG. 2, the loading arms (160) are located on either side of each winding apparatus (120).

[0133] Each loading arm (160) has a first end (162) pivotally mounted to the frame (122) of the winding apparatus (120) at a location at or near a base of the frame (122), and a second end (164) pivotable between raised and lowered positions relative to the frame (122), as indicated by the arrows. The second end (164) includes a gripping unit (166) for gripping and releasing rollers (140).

[0134] In use, each loading arm (160) is able to move to a raised position to grip and remove an exhausted roller (140). The loading arm (160) then moves to a lowered position to exchange the exhausted roller (140) for a replacement roller (140) before moving back to the raised position to fit the replacement roller (140) to the frame (122).

[0135] FIG. 3 shows another embodiment of the invention in which the assembly (100) includes four winding apparatuses (120) each configured to independently wind material about the former (110) and be moveable relative to the former (110) while winding material to form the pipe.

[0136] FIGS. 4 and 5 show another embodiment of the invention in which the assembly (100) is capable of transitioning between horizontal and vertical operating positions.

[0137] Referring to FIG. 4, a portion of the carriage (130) including the racks along which the winding apparatuses (120) move relative to the former is pivotally coupled to a remaining portion of the carriage (130) at one end of the carriage (130). The opposed second end of the carriage (130) includes a ram (not shown) for moving the portion of the carriage together with the former (110) and winding apparatuses (120) between the horizontal and vertical operating positions.

[0138] FIG. 5 shows part of the assembly (100) shown in FIG. 4 in a vertical operating position.

[0139] As shown, in the vertical operation position, the assembly (100) is able to form and insert freshly formed pipe directly into a bore hole (500).

[0140] A method of forming pipe with the assembly (100) as shown in FIG. 1 will now be described in detail.

[0141] As an initial step, each winding apparatus (120) is fully loaded with rollers (140) containing pre-impregnated material via the loading arms (160). Material from each roller (140) is then fastened to the former (110) to ensure material is drawn from the rollers (140) once the frames (122) of the winding apparatuses (120) rotate about the former (110) causing the rollers (140) to orbit the former (110).

[0142] The winding apparatuses (120) then commence pipe formation by winding material about the former (110) while moving in a common direction along the length of the former (110).

[0143] Depending on the type of pipe to be formed, each winding apparatus (120) can be loaded with rollers (140) containing the same type of pre-impregnated material or different types of pre-impregnated materials. Similarly, the winding apparatuses (120) can be configured to wind material about the former (110) in a same direction or in opposite directions.

[0144] For example, if loaded with the same type of material, the winding apparatuses (120) can be configured to wind material about the former (110) in a single direction to hasten pipe formation with each winding apparatus (120) winding material about and along a portion of the former (110) to collaboratively form a length of pipe. The material wound about the former (110) by a trailing winding apparatus (120) will at least partially overlap the material wound about the former (110) by a leading winding apparatus (120) to join the portions together.

[0145] Conversely, the winding apparatuses (120) can be configured to wind the same material about the former (110) in opposite directions to increase the crush strength of the pipe formed. Depending on the desired density and/or thickness, the winding apparatuses (120) can be configured to make repeat passes along the length of the former (110).

[0146] If loaded with different types of material, the winding apparatuses (120) can be configured to form pipe with a liner or a coating.

[0147] For example if forming pipe with a liner, a leading winding apparatus (120) is loaded with rollers (140) containing the lining material and a trailing winding apparatus (120) is loaded with rollers (140) containing the pipe forming material. The leading winding apparatus (120) can then form the liner by winding the lining material about the former (110) and the trailing winding apparatus (120) can form the pipe over the liner by winding the pipe forming material over the top of the lining material.

[0148] If forming pipe with a coating, the leading winding apparatus (120) is loaded with rollers (140) containing the pipe forming material and the trailing winding apparatus (120) is loaded with rollers (140) containing a coating material.

[0149] Once material is wound about the former (110) to a desired density and/or thickness, the winding apparatuses (120) move to a leading end of the former (110) and pause to allow the microwave, UV light or infrared emitting unit to cure the material hardening the material to form pipe.

[0150] Once cured, the former (110) dissociates from the pipe by decreasing in circumference and the carriage (130) moves the former (110) and the winding apparatuses forward to separate the former (110) from the pipe. If a desired length of pipe has been reached, the former (110) is moved clear of the pipe. Otherwise, if further pipe forming is desired, the former (110) is moved almost clear of the pipe leaving a small overlap between the former (110) and the pipe to allow the formation of a continuous length of pipe.

[0151] In some scenarios, the winding apparatuses (120) can temporarily clamp the pipe with their respective mechanical clamps (170) and move towards a trailing end of the former (110) to assist in removing the pipe from the former (110).

[0152] A method of forming pipe with the assembly (100) as shown in FIG. 5 is now described in detail.

[0153] Once the assembly (100) is in place, pipe formation commences by the winding apparatuses (120) winding material about the former (110) while moving in a common direction along the former (110).

[0154] As previously described, each winding apparatus (120) can be loaded with rollers (140) containing the same type of pre-impregnated material or different types of pre-impregnated materials to form pipe with a liner or coating. Similarly, the winding apparatuses (120) can be configured to wind material about the former (110) in a same direction or in opposite directions to vary the strength and/or speed with which pipe is formed.

[0155] Once material is wound about the former (110) to a desired density and/or thickness, the winding apparatuses (120) move to an upper end of the former (110) and pause to allow the microwave, UV light or infrared emitting unit to cure the material hardening the material to form the pipe.

[0156] Once cured, the winding apparatuses (120) temporarily clamp the pipe with their respective mechanical clamps (170). The former (110) then dissociates from the pipe by decreasing in circumference and the winding apparatuses (120) lower the pipe into the bore hole (500) by moving to a lower end of the former (110) while being temporarily clamped to the pipe.

[0157] If a desired length of pipe has been reached, the former (110) is moved clear of the pipe by the winding apparatuses (120) and the mechanical clamps (170) are disengaged.

[0158] If further pipe forming is desired, the winding apparatuses (120) move the pipe almost clear of the former (110) leaving a small overlap between the former (110) and the pipe to allow the formation of a continuous length of pipe. The former (110) then expands to its initial circumference, the mechanical clamps (170) of the winding apparatuses (120) disengage and the winding apparatuses (120) re-commence winding material about the former (110).

[0159] In the present specification and claims (if any), the word comprising and its derivatives including comprises and comprise include each of the stated integers but does not exclude the inclusion of one or more further integers.

[0160] Reference throughout this specification to one embodiment or an embodiment means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases in one embodiment or in an embodiment in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.

[0161] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.