Abstract
A method of reshaping a cylindrical pipe to a ground screw foundation for attaching an object to the ground includes a drawing unit and a working tool having a plurality of press roll disks or press roll disk segments. The press roll disks or press roll disk segments are disposed radially around a longitudinal axis of a holder for the cylindrical pipe, and pivotably around shafts extending at a fixed distance to the longitudinal axis transversely and tangentially relative to the longitudinal axis. A cylindrical pipe is inserted into a holder. The cylindrical pipe or the working tool with the drawing unit is drawn such that a relative movement between the pipe and the working tool is created.
Claims
1. A method of reshaping a cylindrical pipe to provide a ground screw foundation for attaching an object to the ground, the method of reshaping the cylindrical pipe comprising: providing a drawing unit and a working tool having a plurality of press roll disks or press roll disk segments, disposing the press roll disks or press roll disk segments radially around a longitudinal axis of a holder for the cylindrical pipe, and pivotably around shafts extending at a fixed distance to the longitudinal axis transversely and tangentially relative to the longitudinal axis, inserting a cylindrical pipe into a holder, drawing the cylindrical pipe or the working tool with the drawing unit such that a relative movement between the cylindrical pipe and the working tool is created, wherein the press roll disks or press roll disk segments are disposed such that they pivot about respective axes defined by the shafts in response to the relative movement between the cylindrical pipe and the working tool along the longitudinal axis, wherein outer circumferential surfaces of the press roll disks or press roll disk segments having an increasing radius roll off on the cylindrical pipe for imparting a tapering shape to at least one longitudinal section of the cylindrical pipe during said drawing, and wherein at least one spring element provides a preload force that preloads the press roll disks or press roll disk segments so that the press roll disks or press roll disk segments are seated with friction fit against the cylindrical pipe.
2. The method of claim 1, wherein said rolling off of the press roll disks or press roll disk segments during said drawing occurs without applying a drive force at said corresponding shafts for said press roll disks or press roll disk segments.
3. The method of claim 1, wherein the working tool is held in stationary and the drawing unit is moved along the longitudinal axis.
4. The method of claim 1, wherein the cylindrical pipe is held stationary by a retaining unit of the drawing unit and the working tool is moved along the longitudinal axis.
5. The method of claim 1, wherein the cylindrical pipe and the working tool are moved relatively towards each other along the longitudinal axis.
6. The method of claim 1, wherein the cylindrical pipe is rotated around a longitudinal axis thereof during drawing and/or between multiple drawing steps.
7. The method of claim 1, wherein said drawing comprises multiple drawing steps.
8. The method according to claim 7, wherein the multiple drawing steps are applied at differing points in the length of the cylindrical pipe, so as to generate plural tapering sections having differing cross-sections and/or differing gradients on the cylindrical pipe.
9. The method according to claim 8, wherein different sets of press roll disks or press roll disk segments are used so as to generate a plurality tapering sections having differing cross-sections and/or differing gradients on the cylindrical pipe.
10. The method according to claim 1, comprising reshaping first and second cylindrical pipes so that each of the first and second cylindrical pipes has a cylindrical section at one end thereof and a tapering section at the other end thereof, the second cylindrical pipe being of larger diameter than the first cylindrical pipe and the reshaping taking place in the following sequence: reshaping the first cylindrical pipe, inserting the cylindrical end of the reshaped first cylindrical pipe into an end of the second cylindrical pipe, and then reshaping the second cylindrical pipe so that the end thereof into which the cylindrical end of the reshaped first cylindrical pipe has been inserted is tapered and the tapering of the cylindrical end of the second cylindrical pipe effects a press fit of the therein inserted end of the reshaped first cylindrical pipe.
11. The method according to claim 1, comprising reshaping first and second cylindrical pipes so that each of the first and second cylindrical pipes has a cylindrical section at one end thereof and a tapering section at the other end thereof, the second cylindrical pipe being of larger diameter than the first cylindrical pipe and the reshaping taking place in the following sequence: in preparation for the reshaping, inserting an end of the first cylindrical pipe into an end of the second cylindrical pipe and, in that state, reshaping the first and second cylindrical pipes whereby the tapering of the end of the second cylindrical pipe into which an end of the first cylindrical pipe has been inserted effects a press fit of the therein inserted end of the first cylindrical pipe.
12. The method of claim 1 wherein the rolling off of at least some of the press roll disks or press roll disk segments is synchronized by the way of a synchronized coupling.
13. The method of claim 1, comprising forging a tip at an end of the tapered longitudinal section of the cylindrical pipe.
14. The method of claim 1, comprising providing the cylindrical pipe with a helix.
15. The method of claim 14, comprising welding the helix to a periphery of the cylindrical pipe.
16. A method of reshaping a cylindrical pipe to a ground screw foundation for attaching an object to the ground, comprising: providing a drawing unit and a working tool having a plurality of press roll disks or press roll disk segments, disposing the press roll disks or press roll disk segments radially around a longitudinal axis of a holder for the cylindrical pipe, and pivotably around shafts extending at a fixed distance to the longitudinal axis transversely and tangentially relative to the longitudinal axis, inserting a cylindrical pipe into a holder, drawing the cylindrical pipe or the working tool with the drawing unit such that a relative movement between the cylindrical pipe and the working tool is created, wherein the press roll disks or press roll disk segments are disposed such that they pivot about respective axes defined by the shafts in response to the relative movement between the cylindrical pipe and the working tool along the longitudinal axis, wherein outer circumferential surfaces of the press roll disks or press roll disk segments having an increasing radius roll off on the cylindrical pipe for imparting a tapering shape to said at least one longitudinal section during said drawing, wherein at least one spring element provides a preload force that preloads the press roll disks or press roll disk segments so that the press roll disks or press roll disk segments are seated with friction fit against the cylindrical pipe, and said rolling off of the press roll disks or press roll disk segments during said drawing occurs without applying a drive force at said corresponding shafts for said press roll disks or press roll disk segments.
17. A method of reshaping a cylindrical pipe to a ground screw foundation for attaching an object to the ground, comprising: providing a drawing unit and a working tool having a plurality of press roll disks or press roll disk segments, disposing the press roll disks or press roll disk segments radially around a longitudinal axis of a holder for the cylindrical pipe, and pivotably around shafts extending at a fixed distance to the longitudinal axis transversely and tangentially relative to the longitudinal axis, inserting a cylindrical pipe into a holder, drawing the cylindrical pipe or the working tool with the drawing unit such that a relative movement between the cylindrical pipe and the working tool is created, wherein the press roll disks or press roll disk segments are disposed such that they pivot about respective axes defined by the shafts in response to the relative movement between the cylindrical pipe and the working tool along the longitudinal axis, wherein outer circumferential surfaces of the press roll disks or press roll disk segments having an increasing radius roll off on the cylindrical pipe for imparting a tapering shape to said at least one longitudinal section during said drawing, wherein at least one spring element provides a preload force that preloads the press roll disks or press roll disk segments so that the press roll disks or press roll disk segments are seated with friction fit against the cylindrical pipe, reshaping first and second cylindrical pipes so that each of the first and second cylindrical pipes has a cylindrical section at one end thereof and a tapering section at the other end thereof, the second cylindrical pipe being of larger diameter than the first cylindrical pipe and the reshaping taking place in the following sequence: reshaping the first cylindrical pipe, inserting the cylindrical end of the reshaped first cylindrical pipe into an end of the second cylindrical pipe, and then reshaping the second cylindrical pipe so that the end thereof into which the cylindrical end of the reshaped first cylindrical pipe has been inserted is tapered and the tapering of the cylindrical end of the second cylindrical pipe effects a press fit of the therein inserted end of the reshaped first cylindrical pipe.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) The invention will now be described in more detail based on the drawings. In the drawings:
(2) FIG. 1: shows a perspective view of the device according to the invention for producing conical sections 1 on cylindrical pipes 2 of ground screw foundations by way of drawing;
(3) FIG. 2: is a different perspective view of the device according to the invention;
(4) FIG. 2a: is a different perspective view of the device according to the invention in which, in particular, the clamping unit (21) of the drawing and rotating unit (19, 15) and the angle of rotation of the drawing unit are shown in more detail;
(5) FIG. 3: is a sectional view of the device according to the invention of FIGS. 1 and 2, showing the cylindrical pipe 2 inserted into the holder 6 for working purposes;
(6) FIG. 4: is a sectional view of the device according to the invention of FIGS. 1 and 2, showing the end phase of the conical working of the cylindrical pipe 2;
(7) FIG. 5: is the perspective view of a press roll disk segment 3:
(8) FIG. 6: is a sectional view of the device according to the invention;
(9) FIG. 7: is a top view of the device according to the invention comprising the press roll disks or press roll disk segments 3;
(10) FIGS. 8 a to c: show three phases of the process of conically deforming a cylindrical pipe 2;
(11) FIGS. 9 a to c: show three phases of the process of conically deforming a cylindrical pipe 2 having a larger cross-section 17, and having an end region 19 that is to be conically deformed, into which the cylindrical end region 18 of a cylindrical pipe 2 which has a smaller cross-section and is provided with a conical section 1 is introduced and fixed, by way of press fitting, during the conical deformation of the pipe having the larger cross-section;
(12) FIGS. 10 a to c: show three phases of the process of conically deforming a cylindrical pipe 2 having a larger cross-section 17, and having an end region 19 that is to be conically deformed, into which one of the end regions of a cylindrical pipe 2 having a smaller cross-section 16 is introduced and fixed, by way of press fitting, during the conical deformation of the pipe having the larger cross-section 17;
(13) FIG. 11: shows the device according to the invention, comprising a working tool (3), a retaining unit (20) for the pipe (2) that is to be worked, and a drawing and rotating unit (10, 15) having a linear guide (22) for the working tool (3) and/or the retaining unit (20) as well as a further retaining unit (20a) for a cylindrical pipe (2) having a smaller pipe cross-section (16), which can be introduced into the end region (19) of the pipe (2) having the larger cross-section (17) that is to be deformed, so as to be fixed on this pipe;
(14) FIGS. 12 a to f: show six different basic shapes of a single-piece ground screw foundation according to the invention;
(15) FIG. 13: shows a single-piece ground screw foundation according to the invention;
(16) FIGS. 14 a to x: show twenty-four different basic shapes of a two-piece ground screw foundation according to the invention; and
(17) FIGS. 15a and b: shows a two-piece ground screw foundation according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
(18) FIG. 1 shows the device according to the invention for producing at least one conical section (1) on cylindrical pipes (2) of ground screw foundations by way of drawing. The device comprises a plurality of press roll disks or press roll disk segments (4), which are disposed radially around a longitudinal axis (5) of a holder (6) for the cylindrical pipe (2) that is to be drawn, and pivotably around shafts (7) extending transversely and tangentially relative to the longitudinal axis (5), and which are designed so that, with development, the outer circumferential surfaces (8) of the press roll disks or press roll disk segments (3) form a cone.
(19) Also shown are spring elements (11) in the form of gas springs (12), by means of which the press roll disks or press roll disk segments (4) are preloaded.
(20) In addition, a unit (10) for drawing and/or for rotating (15) the pipe (2) is shown, by means of which the pipe (2) can be drawn along the longitudinal axis (5) through the press roll disks or press roll disk segments (4), so that the conical section (1) can be formed by means of the outer circumferential surfaces (8) rolling on the pipe during drawing.
(21) FIG. 2 shows a different perspective view of the device according to the invention of FIG. 1. It differs from the representation of FIG. 1 in that only a single element (11, 12) is shown in the place of the several spring elements (11) in the form of gas springs (12). Moreover, the toothing (13) is shown here, by means of which the press roll disk segments (4) are synchronously coupled to each other.
(22) FIG. 2a is a different perspective view of the device according to the invention of FIG. 2, in which, in particular, the clamping unit (21) of the drawing and rotating unit (10, 15) and the angle of rotation (23) of the drawing unit (15) are shown in more detail. In accordance with the formula alpha=360/number of rolls2, this angle of rotation (23) is established so as to allow for working burrs, which may be created between the effective regions of the press roll disks or press roll disk segments (4), at the smallest angle of rotation possible.
(23) FIG. 3 shows a sectional view of the device according to the invention of FIGS. 1 and 2, comprising press roll disk segments (4) which are disposed radially around a longitudinal axis (5) of a holder (6) for the cylindrical pipe (2) that is to be drawn, and pivotably around shafts (7) extending transversely and tangentially relative to the longitudinal axis (5), and which are designed so that, with development, the outer circumferential surfaces (8) of the disk segments (3) form a cone.
(24) Also shown are spring elements (11) in the form of gas springs (12), by means of which the disks or disk segments (4) are preloaded.
(25) In addition, the cylindrical pipe (2) that is to be worked and inserted into the holder (6) is shown in the position at the start of the working operation by way of drawing.
(26) FIG. 4 shows a sectional view of the device according to the invention of FIGS. 1, 2 and 3, comprising press roll disk segments (4) which are disposed radially around a longitudinal axis (5) of a holder (6) for the cylindrical pipe (2) that is to be drawn, and pivotably around shafts (7) extending transversely and tangentially relative to the longitudinal axis (5), and which are designed so that, with development, the outer circumferential surfaces (8) of the disk segments (3) form a cone.
(27) Also shown are spring elements (11) in the form of gas springs (12), by means of which the disks or disk segments (4) are preloaded in accordance with the representation or the method step according to FIG. 3.
(28) In addition, the cylindrical pipe (2) that is to be worked and inserted into the holder (6) is shown in the position of the final phase of the working operation by way of drawing, which is to say having an already shaped conical section (1) in the form of a cone (9).
(29) In addition, a unit (10) for drawing and rotating (15) the pipe (2) is shown cut in half, and by these means the pipe (2) was drawn along the longitudinal axis 5 through the press roll disk segments (4) so that the conical section (1) was formed by means of the outer circumferential surfaces (8) rolling on the pipe (2) during drawing.
(30) FIG. 5 shows a perspective view of a press roll disk segment (4). It shows the shaft (7) of the segment and the outer circumferential surface (8) thereof, and moreover the toothing (13) in the edge region (14) of the disk (4). In addition, the chamfer is visible, which is used to ensure that the press roll disk segments (4), when installed, are clear of each other during development, while the pipe section (2) is deformed into the cone (9), and adjoin each other as seamlessly as possible so as to achieve a cone surface that is uniformly deformed and clean to as great an extent as possible.
(31) FIG. 6 shows a top view of the device according to the invention. The press roll disk segments (4) and the outer circumferential surfaces (8) thereof can be seen. Also shown is the holder (6) for the pipe (2) that is to be worked and the longitudinal axis (5). Fastening bores for holding lugs for preload elements (11, 12) for the disks or disk segments (4) are likewise shown.
(32) FIG. 7 shows a top view of the device according to the invention. The press roll disk segments (4) and the outer circumferential surfaces (8) thereof can be seen. Also shown is the holder (6) for the pipe that is to be worked and the longitudinal axis (5). The toothing (13) of the press roll disk segments (4) provided at the disk edges (14) is also indicated. The thickness of the disks or disk segments (4) is such that, not only can the high deformation forces be transmitted, but the disks (4) are only just clear of each other at the smallest cone diameter, yet are seated against the cone surface over almost the entire circumferences thereof.
(33) FIGS. 8 a to c show the process of conically deforming a cylindrical pipe (2) in three phases. The cylindrical pipe (2) here has already been provided with a conical section (1) (in an earlier operation). FIGS. 8 a to c show the process of further conically deforming the conical section (1) in three steps.
(34) In FIG. 8a, the pipe (2) that is to be deformed is inserted into the device so far that the smallest radius of press roll disk segments (4) comes in contact with the surface of the pipe (2) that is to be deformed, at exactly the point at which further deformation into a longer cone section (1) on the pipe (2) starts.
(35) FIG. 8 b shows that the process for the further conification has already been half way completed. The final cone (1) that is to be attained is indicated by the dash-dotted line. And finally,
(36) FIG. 8 c shows the state of conification in which the smallest conification diameter has been reached by way of the press roll disk segments (4) that formed this region of the smallest cone diameter, with the largest radii of press roll disk segments (4) located opposite each other.
(37) FIGS. 9 a to c show three phases of producing a ground screw foundation having two conical sections (1) from cylindrical pipes (2) having differing cross-sections (16, 17).
(38) The figures show a cylindrical pipe (2) having a larger cross-section (17), which was introduced into the holder in the longitudinal axis (5) of the holder (6).
(39) Also shown is a further cylindrical pipe (2) having a smaller pipe cross-section (16) and a conical section (1), the cylindrical end region (18) of the pipe being axially aligned with the end region (19) of the pipe having the larger cross-section (17), which is to be conically deformed, for the purpose of being introduced into this second end region.
(40) Also shown are press roll disk elements (4), which are mounted pivotably on shafts (7), and the outer circumferential surfaces (8) thereof for generating a conical section 1 at the end region (19) of the pipe (2) having the larger pipe cross-section (17) which is to be conically deformed.
(41) FIG. 9a shows the device after inserting the cylindrical pipe (2) having the larger pipe cross-section (17), with the longitudinal axis (5) thereof in the holder (6). The pipe (2) and the press roll disk segments (4) are located in the open position, which is the position in which the working of the end region (19) which is to be conically deformed is to start, by way of drawing out the pipe (2) and roll-like rolling of the outer circumferential surfaces (8) of the press roll disk segments (4). The cylindrical end region (18) of the pipe (16) having the smaller pipe cross-section has not yet been introduced into the end region (19) of the pipe (17) having the larger pipe cross-section which is to be conically deformed.
(42) FIG. 9b shows the same device after insertion of the cylindrical end region (18) of the pipe (2) having the smaller pipe cross-section (16) into the end region (19) of the pipe (2) having the larger pipe cross-section (17), which is to be conically deformed.
(43) The cylindrical pipe (2) having the larger cross-section (17) in this illustration has already been drawn approximately half way. The deformation of the end region (19) of the pipe (2) having the larger pipe cross-section (17) which is to be conically deformed has already been partially completed.
(44) FIG. 9c shows the state at the end of the drawing and deformation process. The deformation of the end region (19) that is to be conically deformed is completed. The portion of the pipe (2) having the smaller cross-section (16), which has been inserted into the end region (19) of the pipe (2) having the larger cross-section (17), which is to be conically deformed, is fixed there by press fitting as a result of the conical deformation of the latter.
(45) FIGS. 10 a to c show the same device and the same working steps of deforming an end region (19) of a cylindrical pipe (2) having a larger cross-section (17) and of integrally connecting a cylindrical pipe (2) having a smaller cross-section (16), the cylindrical end region 18 of which is introduced into the end region of the pipe (2) having the larger cross-section (17) which is to be conically deformed, and is fixed there with press fitting during the conical deformation of the end region 19 of the pipe having the larger cross-section 17 which is to be conically deformed, as is shown and described for FIGS. 9a to c.
(46) Thus, FIGS. 10 a to c differ from FIGS. 9 a to c only in that the cylindrical pipe (2) having the smaller cross-section (16) does not have a conical section (1), but instead has a substantially undeformed cylindrical shape. Substantially undeformed shall mean that a certain degree of deformation of the cylindrical pipe (2) having the smaller pipe cross-section (16) is produced only in the connecting region, in which the two pipe parts were formed together or pressed together with press fitting.
(47) FIG. 11 shows a device according to the invention comprising a working tool (3) composed of press roll disk segments (4), which are arranged around the longitudinal axis (5) of the holder (6) on shafts (7). A cylindrical pipe (2) having a larger pipe cross-section (17) is located in the holder (6) in longitudinal alignment with the longitudinal axis (5) of the holder (6).
(48) The pipe is inserted into the holder (6) so far that the press roll disk segments (7) are in the largest open positions thereof, and are seated against the pipe for the conical deformation thereof. The pipe (2) is held in a stationary manner and in the longitudinal axis (5) of the holder (6) by a retaining unit (20), by means of a clamping unit (21), and potentially also rotated by the rotating unit (15) during working, and/or drawn by the drawing unit (10) with linear guidance by the linear guide (22).
(49) The working tool (3) is in turn linearly guided along the longitudinal axis (5) of the holder (6) by means of the linear guide (22) and can be rotated by a rotating unit (15) and/or drawn by the drawing unit (10). This configuration includes the option of moving only the working tool (3) by way of the rotating and/or drawing unit (10, 15), or of moving only the retaining unit (20) using the rotating and/or drawing unit (10), or moving both the working and the retaining units (3, 20) relative to each other.
(50) A cylindrical pipe (2) having a smaller pipe cross-section (16) is held by a further retaining unit (20a) comprising a clamping unit (21a) in alignment with the longitudinal axis (5) of the holder (6) and is guided along the longitudinal axis (5) of the holder (6) by means of the linear guide (22) so that it can be inserted into the end region (19) of the pipe (2) having the larger cross-section (17) which is to be conically deformed so as to be fixed to this pipe.
(51) FIGS. 12 a to f show different embodiments of a single-piece basic ground screw foundation shape. FIG. 12 a shows a base body of a ground screw foundation having a cylindrical pipe section 2, which transitions into a conically tapering pipe section 1. The cylindrical pipe section 2 has an outside pipe diameter D at the larger cross-section 17. A bend-shaped transition 24, which is to say an edge, is formed between the cylindrical and conical pipe sections. The edge is shown by the peripheral line on the base body. In contrast, FIG. 12 b shows the transition by way of a tapering, convex region 25. The lateral region of the basic ground screw foundation shape transitions continuously, which is to say essentially without an edge, from a cylindrical section 2, via the convex transition region 25, into the conical section 1.
(52) FIGS. 12 c to f have an S-shaped contour, which is to say the basic shape of the ground screw foundation has two cylindrical pipe sections 2, 2, between which a conical section 1 is formed. The second cylindrical pipe section 2 has a diameter d. The transitions between the cylindrical sections 2, 2 and the conical section 1 are designed as bend-shaped transitions 24, respectively, according to FIG. 12 c. In contrast, FIG. 12 d shows the transition between the cylindrical pipe section 2 and the conical pipe section 1 as a continuous, convex transition region 25. The convex radius R is at least five times the pipe diameter D at the larger cross-section 17 of the cylindrical pipe 2. According to FIG. 12 e, which shows a variant of the embodiment of FIG. 12 c, the transition between the conical section 1 and the cylindrical pipe section 2 is designed as a concavely tapering transition region 26. The embodiment according to FIG. 12 f has a convex transition 25 between the cylindrical pipe section 2 and the conical pipe section 1, and a concave transition region 26 between the conical section 1 and the cylindrical pipe section 2. With such an embodiment having at least one concave or a convex transition 25, 26, the conical section 1 can also be designed infinitesmally short, so that the length thereof moves toward zero and a continuous transition occurs from the convex region 25 into the concave region 26.
(53) FIG. 13 shows a single-piece base body of the ground screw foundation according to FIG. 12 f, which was produced by the method according to the invention and in which, in further method steps, a tip 27 is forged and a screw helix 28 is welded on the periphery.
(54) FIGS. 14 a to x show the basic shapes of different two-piece ground screw foundations produced by a method according to the invention, wherein the basic shapes can essentially be produced by combining the single-piece variant of the basic shapes according to FIGS. 12 a to f. As is shown in FIGS. 9 a to c, the two elements of the two-piece design are joined between the cylindrical end region of the first pipe having the smaller pipe cross-section 18 and the conically deformed end region of the second pipe having the larger pipe cross-section 19. A joining region, in which the two cylindrical pipes 2 are connected by way of press fit, is shown in detail A of FIG. 15.
(55) The embodiments according to FIGS. 14 a, b, g, h, m, n, s, t have two substantially tubular sections 2, 2 and have a conical section 1 at the lower end. The remaining embodiments have three tubular sections 2, 2, 2 and two conical sections 1, 1 arranged downstream between two tubular pipe sections 2, 2, 2, respectively. The transitions between the individual sections are designed as a bend-shaped transition 24, as a convex transition region 25, or as a concave transition region 26.
(56) FIG. 15a shows a two-piece basic shape according to FIG. 14 x, which in a further work step is provided with a tip 27 and a screw helix 28, so that it can be used as a ground screw foundation.
(57) FIG. 15b shows the joining region in more detail, in which the two pipes 2 overlap.
