EP4267336A1

EP4267336A1 - Method for producing a polymer-improved pipe element

Info

Publication number: EP4267336A1
Application number: EP21844016.2A
Authority: EP
Inventors: Thomas Cramer
Original assignee: Minimax Viking Research and Development GmbH
Current assignee: Minimax Viking Patent Management GmbH
Priority date: 2020-12-23
Filing date: 2021-12-23
Publication date: 2023-11-01
Also published as: US20240102598A1; WO2022136644A1

Abstract

The invention relates to a method for the automated or partially automated production of a polymer-improved pipe element (100) using pipe sections (101, 102) having tolerances, the method comprising the following steps: Providing a first pipe section (101) and a second pipe section (102), the pipe sections each having a connection region which is provided for connection to the respective other pipe section; detecting a spatial shape of the first pipe section and a spatial shape of the second pipe section, in each case in the connection regions; determining a spatial penetration curve as a function of overlaying the spatial shapes; determining a cut contour in the connection region of the first pipe section and a cut contour in the connection region of the second pipe section, in each case as a function of the penetration curve; generating edge surfaces (115, 117) in the connection regions of the first and the second pipe section along the respective cut contours; aligning the generated edge surfaces of the pipe section to one another; and welding the first and the second pipe section along the edge surfaces aligned to one another along the determined spatial penetration curve. The invention also relates to a device for the automated or partially automated production of a polymer-improved pipe element.

Description

Process for manufacturing a polymer-coated tubular element

The invention relates to a method for the automated or semi-automated production of a polymer-coated tube element using tube sections that are subject to tolerances.

The manufacture of polymer-coated tubular elements for fire extinguishing systems is known, for example, from EP 2623163 B1, EP 2766653 B1 and WO 2020/002502 A1. The possibility of applying a highly corrosion-inhibiting and long-term resistant coating to the pipe by means of polymer refinement is becoming increasingly important in areas of application in which long-term resistance to corrosion is increasingly important for safety reasons. A noteworthy example of such applications is the use of polymer-coated raw elements in fire extinguishing systems, but also the use of such polymer-coated pipe elements in industrial plants with corrosive media that have to be transported, or in corrosive environments, such as fluid line systems in the maritime environment, are increasingly relevant areas of application.

It is known that it is important for the coating success in polymer refinement to avoid potential subsequent sources of corrosion in pipe manufacture. It is also known, e.g. In the area of the weld seam, due to contamination, shape deviations and other aspects, such corrosion nests can form or the coating can develop incorrectly due to surface artifacts. It is also known that most such problem areas on the inside of the pipe can be eliminated quite reliably in the subsequent pickling process with complete root detection during the welding process.

In practice it has been found that the production of a tube element from several tube sections by means of welding poses particular challenges when tubes subject to tolerances are used, which can differ from tube to tube with regard to their wall thickness, roundness and tube bend. However, the use of such pipes is desirable for economic reasons and especially for applications in which very large quantities, i.e. pipe lengths, have to be processed.

It was therefore the object of the invention to provide a method of the type described in the introduction, in which the disadvantages described above are overcome as far as possible. In particular, the invention was based on the object of specifying a method of the type described at the beginning, which allows an economically favorable production of tubular elements without impairing the quality of the surface coating by means of polymer refinement.

The invention solves the underlying problem with a method of the type described in that it has the following steps:

- providing a first pipe section and a second pipe section, the pipe sections each having a connection region which is provided for connection to the other pipe section in each case;

- detecting a spatial shape of the first pipe section and a spatial shape of the second pipe section, respectively in the connection areas;

- determining a spatial common penetration curve as a function of a superposition of the spatial shapes,

- determining a cutting contour in the connection area of the first pipe section and a cutting contour in the connection area of the second pipe section, each as a function of the common penetration curve;

- Generating edge surfaces in the connection areas of the first and second tube sections along the respective cutting contours;

- Aligning the generated edge surfaces of the pipe sections to one another; and - Welding the first and second pipe sections along the mutually aligned edge surfaces along the determined spatial penetration curve.

Pipes subject to tolerances are understood to mean, for example, pipes in which the deviations in the outside diameter were up to +/- 1%, which would correspond to a tolerance band of approx. 4 mm for a nominal diameter of DN200. The tolerance of the pipe elements with regard to the wall thickness can be +/-10% for pipes subject to tolerances within the meaning of the invention, so that the inner contour can also have a tolerance range of up to 0.4 mm for a pipe with a diameter of DN200. The accuracy of shape can be up to 2% for pipes subject to tolerances and the deviation in straightness can be 3mm per meter.

The invention makes use of the finding that by determining the spatial penetration curve on the basis of the spatial shape of both pipe sections, a set of references can be provided for the shape to be introduced into both pipe sections, which ensures an exact correspondence of the shape of the first and second pipe sections in their connection area, regardless of the tolerance-related shape deviations that occur in practice.

With the invention, it is possible to process pipes that are already quite precisely dimensioned and tolerated ex works, but also pipes that have the tolerance ranges described above, or even have greater deviations than those. In other words, the common spatial penetration curve makes it possible to introduce the exact external shape of the first pipe section as a cut edge in the second pipe section when the second pipe section is a nozzle and the first pipe section is an elongate base pipe. On the other hand, the common penetration curve enables the exact shape of the second pipe section to be cut out into the first pipe section.

Preferably, the step of welding the first and second pipe sections together is performed in a single continuous motion. That is, the welder is set up and travels the common spatial penetration curve in one pass to complete the weld without stopping in between. The welding device is preferably not set down until the point of attachment has been reached again and, in particular, when the root formations of the weld seam are connected to one another. As a result, a desired weld seam quality, for example class B according to DIN EN ISO 5817:2014 or other analogous standards, reliably achieved. The procedure is made possible by determining and then using the common spatial penetration curve. The weld seam formed in a single continuous pass is thus formed more regularly than manual or semi-automated weld seams can be, which in turn improves the ability of the tubular element to form a low-defect or defect-free surface coating by means of polymer refinement.

Preferred embodiments of the method according to the invention are described in the claims and in the following explanations.

In a first development of the method, the step of determining the three-dimensional shapes includes providing an idealized model of the first pipe section and an idealized model of the second pipe section, and determining deviations of the detected shape of the pipe sections from a respective model. The idealized models are, for example, cylinders with the specified theoretical outside diameters of the pipe sections. The outer diameter is the size that is also measured. In other words, the actual deviations of the pipe sections from their target geometry are detected in this method step.

In a development of the method, the step of determining the spatial penetration curve includes providing or generating an idealized penetration curve of the idealized models, and generating the spatial penetration curve by applying the deviations of the spatial shape to the idealized penetration curve.

In an alternative preferred embodiment, the step of determining the three-dimensional shapes includes determining groups of points for both pipe sections, the groups of points lying on the respective surface of the pipe sections in the respective connection area and characterizing the three-dimensional form of the pipe sections in the connection areas, and preferably also the step of determining the spatial penetration curve comprises forming the spatial penetration curve from the intersection of the sets of points. In other words, according to this variant, those points are found which have the same coordinates in both sets of points. If the two detection steps are not carried out in the same coordinate system, the groups of points are preferably transposed into a common coordinate system. The advantage of the invention is particularly evident here: using the common spatial penetration curve, it is possible in a semi-automated or automated process to carry out all the steps of mechanical processing of the pipe sections, such as their positioning in the system, the creation of the edges in the connection areas for to carry out the subsequent welding, the cleaning and dressing of the cut surfaces produced, and the welding itself, all on exactly the same path as a function of the spatial penetration curve. As a result, sources of error that could be associated with inaccurate positioning or that could result from unforeseen shapes of the pipe sections are largely ruled out.

The method is preferably further developed in that it includes the step of clamping the first pipe section by means of a clamping device, preferably in such a way that the first pipe section is held rotatably about an axis of rotation of the clamping device. In other words, the first tube section is preferably clamped so as to be rotatable about a defined instantaneous center, which would represent the theoretical center of the tube if it corresponded to an idealized cylinder. The rotating function can be implemented, for example, by rotating the entire clamping device about this central pipe axis, which also forms the so-called tool center point (TCP) of the common coordinate system, or by rotating only the first pipe section. In principle, the method according to the invention can also be carried out if the pipe section is not able to rotate.

More preferably, the method includes the steps of picking up the second pipe section by means of a handling device, in particular a handling robot, and positioning the second pipe section in a fixed position relative to the first pipe section. In a first preferred variant, the handling device continuously holds the second pipe section in the fixed position relative to the first pipe section until the welding has been carried out. In a preferred second alternative, the second pipe section is held by the handling device only until it has been mechanically fixed in some other way relative to the first pipe section, for example by means of tack welding.

In a further preferred embodiment of the method, the step of producing the edge surfaces includes the cutting of peripheral edge surfaces on the first and second tube section, preferably by means of plasma cutting, with preferably Edge surfaces are cut on the first and second pipe section, each with an inner edge and an outer edge.

More preferably, the edge surfaces on the first and second pipe sections are cleaned prior to the welding step.

More preferably, the edge surface to be generated on the first pipe section is at a distance from its front ends and defines a cutout through the wall of the first pipe section, and the edge surface to be generated on the second pipe section is formed on a front end of the second pipe section. In other words, the first pipe section is a base pipe with a lateral recess spaced apart from the front end, and the second pipe section is a socket designed for lateral attachment to the first pipe section, which is aligned flush with this cutout.

The first and second tube sections are preferably aligned at an angle of 90° +/- 0° to 5° to one another.

Alternatively or additionally, the first and second tube sections are preferably aligned in such a way that they rest against one another without a gap or there is a joint gap of 0.2 mm or less.

The method preferably also includes the step of providing the first and second pipe sections, step by step, of scanning the identification of the pipe sections to be processed. By scanning corresponding markings in pipe sections, it is realized that the (theoretical) nominal diameters, wall thicknesses, etc. of the pipe sections to be processed can be recorded for the automation of the welding. This recorded information can be used, for example, for the automatic setup of the handling devices, the clamping device and so on.

In a further preferred embodiment, the step of welding the first and second pipe sections comprises welding the pipe sections along the penetration curve; forming a fully circumferential weld having a root extending to the inside of the pipe sections, the root of the weld having a thickness such that at least one of the inner edges, and preferably both inner edges, is or are fully engaged by the root , wherein the root of the weld seam completely covers the inner edge of one of the pipe sections, and the remaining inner edge of the other pipe section is spaced apart from the weld seam by a predetermined maximum value in the radial direction, in particular the predetermined maximum value, a) provided that the first and second pipe sections have the same wall thickness have, is less than or equal to half the wall thickness of the pipe sections, particularly preferably less than or equal to a quarter of the wall thickness of the pipe sections, or b) if the first and second pipe sections have different wall thicknesses, less than or equal to a difference in the wall thicknesses of the pipe sections, particularly preferably smaller or equal to half the difference in wall thickness of the pipe sections.

The method according to the invention preferably also includes the step of applying a polymer-based layer to the inside of the tubular element, the polymer-based layer completely covering the inside of the tubular element, the polymer-based layer preferably being applied by means of autodeposition, more preferably by immersing the tubular element in an immersion bath , which contains a corresponding coating agent, in particular a polymer-based chemical autodeposition material. This process step, in which the polymer finish is added to the tube, can be used successfully with various chemical autodeposition materials, for example. For example, epoxy-acrylic urethane coatings such as Bonderite M-PP 930 have proven suitable in the past. The properties of these autodeposition materials are well known, and these materials are easy to control in the coating process, even on an industrial scale. The autodeposition coating is described, for example, in the publications referred to at the outset, the content of which is included here in its entirety.

The invention has been described above in a first aspect with reference to the method explained. In a further aspect, the invention also relates to a device for the automated or semi-automated manufacture of a polymer-coated tube element using tube sections subject to tolerances, the tube sections each having a connection region which is provided for connection to the respective other tube section.

The invention solves the task on which it is based in that the device has at least one detection device for detecting a spatial shape in each of the connection areas, a computing unit that is set up for this purpose, as a function a superimposition of the detected spatial shapes to determine a spatial penetration curve, and as a function of the penetration curve to determine cutting contours in the connecting areas of the first and second pipe section, a cutting device for producing edge surfaces in the connecting areas of the first and second pipe section along the respective cutting contours, and comprises a welding device which is set up to weld the first and second pipe sections to one another along the mutually aligned edge surfaces along the determined spatial penetration curve.

The device makes use of the same advantages and preferred embodiments as the method according to the invention in accordance with the first aspect, so that in this respect reference is made to the above explanations to avoid repetition. Preferred embodiments of the method are at the same time preferred embodiments of the device and vice versa.

In a preferred development of the device, the device has a device for collecting welding, cutting beam or other artefacts that are flung away by the welding or cutting beam from the point of processing, for example welding spatter, blown liquid metal from the plasma cutting process, or flying chips, on the inside of the first and/or second pipe section, which is designed to be positioned before the welding in the connection areas of the first and/or second pipe sections, particularly preferably substantially opposite the welding or cutting point. This reduces or prevents damage to and contamination of the inner surface, and thus also reduces the risk of impairment of the surface quality inside the pipe.

For this purpose, the device preferably has a collecting container which is adapted to the inner diameter of the first pipe section and is set up to collect as many of the artifacts mentioned above as possible. Catching the artifacts, which according to the invention also takes place in a partially automated or automated process, is described in more detail, for example, in WO 2020/002486A1, the content of which is included here in its entirety.

In a preferred embodiment, the device according to the invention has a clamping device for the first pipe section and a handling device, in particular a handling robot, for the second pipe section. The clamping device preferably has at least one clamping device, preferably a plurality of clamping devices, and is set up to rotate the first pipe section about an axis of rotation, with the axis of rotation of the clamping device preferably running through the origin of the coordinate system of the common spatial penetration curve in its clamping position, or with the common spatial penetration curve is, if necessary, transposed into the coordinate system, one axis of which represents the axis of rotation. If the first pipe section was already clamped before the three-dimensional shape was recorded, the recording and thus also the determination of the common penetration curve can be carried out directly in the correct coordinate system, so that a transposition can be omitted.

In a further preferred embodiment, the clamping means comprises a clamping center which defines the axis of rotation of the clamping device. In further preferred embodiments, the clamping means described above is a first clamping means and the clamping device also has a second clamping means, which is arranged at an axial distance from the first clamping means along the axis of rotation, the clamping device being set up to clamp the first pipe section to both of them by means of the clamping means to stretch sides of the connection area. It is fundamentally advantageous here to choose the distance between the clamping means as small as possible.

Particularly preferably, the clamping means can be moved relative to one another in the direction of the axis of rotation, so that the clamping distance between the clamping means can be adjusted as a function of the diameter of the second pipe section. The smaller the distance between the clamping means can be selected, the smaller is a wobbling movement of the first pipe section during its rotation. The wobbling movement inevitably arises due to a radial offset between the axis of rotation of the clamping device and the center of mass of the first pipe section, because the pipe section does not have an idealized cylindrical shape, but is also subject to tolerances with regard to its straightness.

In addition, the pipe section is preferably clamped as a function of the expected deformation of the pipe section as a result of the forthcoming introduction of heat. This reduces the influence of the thermally induced deformation on the calculated weld path. This means that the deflection of the surface of the first pipe section is, in absolute terms, less, even in the case of bent, odd pipe sections, which facilitates the positional tracking of the handling device which is to carry out the welding operation.

In a further preferred embodiment, the clamping means or means is/are designed to be open on one side and set up to receive and clamp the first pipe section from above. The design of the clamping devices that is open on one side achieves two advantages at the same time: On the one hand, the tubular elements can be inserted into the clamping device from above, which makes handling in automated production much easier and reduces the space requirement. On the other hand, the open area above the clamping device can offer better access to the connecting section of the pipe sections for the handling device or devices.

In a further preferred embodiment, the first and/or second clamping means are set up to fix the pipe section, and the clamping device or the clamping means are set up to pivot the clamping means in such a way that the first pipe section rotates around the axis of rotation of the clamping device. It can be advantageous to rotate the entire clamping device and to fix the clamping means relative to the clamping device.

In a preferred embodiment, the clamping means are designed as centrally clamping clamping devices, particularly preferably as steady rests.

In a further preferred embodiment, the tensioning device has an arcuate guide along which the tensioning means is movably received, the guide being concentrically aligned relative to the axis of rotation and adapted to guide the tensioning means around the axis of rotation. If several clamping means are used, preferably at least one, preferably several or all of the clamping means are arranged such that they can be moved about the axis of rotation by means of a separate guide of this type.

In a further preferred embodiment, the handling device is a first handling device; the device also has a second handling device, in particular designed as a handling robot, which has a receptacle for various processing attachments. The essays - also referred to as working heads - here preferably include one or more of the following: To form the Cutting device a cutting torch, laser, water jet or a processing head for machining (including post-machining of the cutting edges, in particular for milling); as a cleaning device, an attachment for hammering, blasting, scraping, brushing, or plasma blasting; a mechanical surface sensor, a dynamic pressure sensor, a plasma surface sensor, one or more optical sensors to form the detection device; to form the welding device, a welding head, for example a MIG, MAG or TIG welding head, or in the case of soldering, a soldering device instead of welding.

The attachments preferably each have an assembly interface designed to correspond to the receptacle of the manipulator and have an active point (tool center point). The point of action is, for example, the marking tip in the case of a marking pen, the welding point in the case of a welding attachment, etc.. The point of action is particularly preferably identically positioned for all attachments relative to their assembly interface. This has the effect that the tools, when guided by the handling device along the same path, perform exactly the same movement through space with their point of action. This in turn means that a number of tools, for example the measuring attachment, the flame cutting attachment and/or the welding attachment, can be guided using a single track. A separate path does not have to be programmed or calculated for each tool. In this preferred embodiment, the spatial penetration curve only has to be calculated once, which can then be used for all work steps despite any tool changes. As a result, considerable computing and time resources can be saved and manufacturing tolerances can be reduced at the same time.

The device preferably has an electronic machine control, which is connected in a signal-conducting manner to the detection device, the computing unit, the cutting device, the welding device and preferably one, several or all of the clamping device, the first and/or the second handling device and is set up to carry out the method to carry out one of the preferred embodiments described above.

The machine control can be designed as a higher-level control device, which communicates with one, several or all of the aforementioned devices in a signal-conducting manner and controls them, or can have one or more sub-control units have, which are respectively assigned to the devices described above, and each make a dedicated control of the respective units.

The program architecture will be adapted depending on the application and the machine concepts available to the respective plant operator. For example, the electronic machine control as a higher-level control could control two mechanical systems, each with a CNC control.

The machine control preferably has a higher-level programmable logic controller (PLC), as well as a man-machine interface, and more preferably functional units such as order management and control of the peripheral devices of the device. The two mechanical systems each have a dedicated CNC controller and a handling device designed as a six-axis robot. The first mechanical system is preferably responsible for the first pipe section and the second mechanical system is responsible for the second pipe section.

The first mechanical system preferably has a positioning device for the pipe, which has the clamping device, and a sensor system for measuring the surface, which has the detection device. Furthermore, the first mechanical system has processing hardware for cutting the first pipe section and for welding the pipe connection between the two pipe sections, both of which are preferably operated by means of the handling device.

The second mechanical system preferably also has a handling device designed as a six-axis robot and is responsible for handling and positioning the second pipe section, preferably a pipe socket. The second mechanical system preferably also has a sensor system for measuring the surface, which represents the detection device, and the hardware for cutting the second pipe section to size and for positioning the socket for the joining or for the joining itself, if necessary.

The invention has been described above on the basis of the first and second aspects in relation to the method according to the invention and the device according to the invention. The invention also relates to a computer program product, comprising instructions which, when the program is executed by a computer, preferably by the machine control of the device, cause the latter to then carry out the steps of Carry out the method according to a preferred embodiment described above.

The invention also relates to a computer-readable storage medium comprising instructions which, when the instructions are executed by a computer, preferably by the machine control of the device described above, cause the latter to then carry out the steps of the method according to one of the preferred embodiments described above.

The invention also relates to the use of a tubular element produced by a method according to one of the preferred embodiments described above or by means of a device according to one of the preferred embodiments described above in a pipeline system of a fire extinguishing system. Alternatively, the invention relates to such a use of a tubular element in a pipeline system of a watercraft, or as a gas or liquid line in an industrial plant, for example in a marine environment.

The invention demonstrates its advantages wherever stainless steel pipelines have always been used in the past for reasons of corrosion protection. By mastering the welding process, even with pipes subject to tolerances, it offers the possibility of significantly increasing the safety and economic efficiency of the construction of such systems without sacrificing corrosion resistance.

The invention also relates to a polymer-coated pipe element, which has a first pipe section and a second pipe section, which are connected to one another by means of a continuous weld seam and are coated with a polymer-based layer at least on the inside of the pipe, but preferably on the inside of the pipe and on the outside of the pipe, wherein the polymer-based layer is chemically bonded to the material of the tubular member, and preferably includes a polymer-based autodeposition material.

The tubular member incorporates the advantages of the method and apparatus of the two aspects mentioned herein. Preferred embodiments of the method and the device are at the same time preferred embodiments of the tube element and vice versa. Because the first and second tube sections have been welded in a continuous, i.e. a single uninterrupted movement, the tube element has a specially shaped weld seam which—as explained above—is formed more regularly than manually or semi-automatically produced weld seams can be. Due to its production in an uninterrupted pass, the weld seam has in particular exactly one attachment point, at which the deposition point is also located. The regular formation can be visually checked both outside and inside (see also the above explanations on root detection) on the tubular element, and with it the ability of the tubular element to form a low-defect or defect-free surface coating by means of polymer refinement.

On the first pipe section, the pipe element preferably has a nominal diameter in a range from DN16 to DN500, more preferably in a range from DN20 to DN300, particularly preferably DN32 to DN65, with the nominal diameter of the second pipe section being less than or equal to the nominal diameter of the first pipe section.

The first pipe section preferably has a flattened surface in a wall area, preferably in that area in which the weld seam is formed.

The wall thickness of the tube sections is preferably in a range between 2 mm and 10 mm, preferably in a wall thickness range of 5 mm to 6 mm.

It should be noted at this point that it is possible with the method according to the invention to produce tubular elements with significantly greater wall thicknesses, because the method according to the invention described above can also be carried out with multi-layer welding, again guided by the spatial penetration curve, in which case wall thicknesses can certainly also be connected to one another in the range from 30 mm to 40 mm. Each of the weld layers benefits from the possibility of uninterrupted continuous welding without intermittent settling, thanks to improved uniformity, which manifests itself, among other things, in less pronounced flaking.

With the method according to the invention and the device according to the invention, thin-walled pipes can also be soldered as an alternative to a welding process. The tubular element produced with the method and the device according to the invention preferably has a polymer finish with a layer thickness in a range from 7 μm to 80 μm, preferably in a range from 7 μm to 30 μm, the layer thicknesses being based on the dry layer thickness and in particular refer to the increase in layer thickness relative to the untreated condition.

In the area of the connection area and towards the front ends of the pipe, the layer thicknesses are preferably greater than in the central areas, which are spaced apart from both the one and the other end of the pipe sections.

The invention is described in more detail below with reference to the accompanying figures and with reference to possible exemplary embodiments. This shows:

1 : an automatic process flow chart of the method according to the invention for producing a tubular element according to a preferred embodiment;

FIG. 2a: a schematic three-dimensional representation of a tube element, produced according to the method according to FIG. 1;

FIG. 2b: a partial view of a tubular element according to the invention according to FIG. 2a in section;

3a, b: overall views of the device according to the invention for producing a pipeline element from the front and the side;

4a-9b: Partial views of the device according to the invention for producing a pipeline element in different steps according to an embodiment of the method according to the invention;

10: a detailed view of the device according to the invention with its angular positioner for receiving and moving a first pipe section; and

Fig. 11: a schematic representation for the determination of the spatial penetration curve. FIG. 1 shows a schematic sequence of a possible embodiment of the method according to the invention for producing a polymer-coated tubular element 100 (FIG. 2). First, in steps 1a, 1b, a first pipe section 101 and a second pipe section 102 are provided. The first pipe section 101 is, for example, a base pipe, and the second pipe section 102 is a pipe socket that is to be welded to the first pipe section 101 as a lateral outlet.

Then, in a next method step 3a, 3b, the three-dimensional shape of the first and the second pipe section 101, 102 is recorded, which is intended to form the subsequent connection area of the pipe sections 101, 102. In particular, the surfaces of the tube sections 101, 102 to be connected are scanned in order to detect any deformations or irregularities in the design of the tube element.

Between steps 1 and 3, the first pipe section 101 is preferably clamped in a clamping device, for example a clamping device 40 according to the second aspect of the invention. Those will be described in more detail below. Furthermore, the second pipe section is preferably picked up by means of a handling device, such as a (first) handling device 52 which is designed as a handling robot, see FIG. 8b.

The spatial shape of the first pipe section 101 is detected, for example, by means of a (not shown) stationary detection device along which the pipe section 101 is guided, or by means of a (second) handling device 50, which can be designed as a handling robot.

The spatial shape of the second pipe section 102 is detected, for example, by means of a stationary detection device (not shown) along which the pipe section 102 is guided, or by means of the second handling device 50, which can be moved relative to the first handling device. The second handling device can, for example, have a number of different work attachments, one of which would be the detection device.

In a subsequent method step 5, a spatial penetration curve is then determined as a function of superimposing the spatial shapes of the first and second pipe section, preferably by means of a computing unit 46. The spatial penetration curve serves as a central control variable for the following Process steps up to and including the welding of the pipe sections 101, 102 to one another.

The work attachments preferably each have the same point of action relative to the handling device, so that all work attachments can be moved along the same path, namely along the common penetration curve, without additional programming effort being necessary.

On the basis of the penetration curve, in particular also by means of the computing unit 46, a cutting contour in the connection area of the first pipe section 101 and a cutting contour in the connection area of the second pipe section 102 are then determined.

In subsequent method steps 7a, b, in preparation for the welding, edge surfaces are produced on the tube sections 101, 102 by means of a cutting device, preferably by means of plasma cutting. The edge surfaces on the first pipe section 101 are preferably produced by means of the second handling device 50, which for this purpose accommodates a corresponding working head as a cutting device.

The edge surfaces on the second pipe section 102 are preferably produced by means of a stationary part of the cutting device or by means of the second handling device. In steps 7a, b, the tube sections are given either edge surfaces 115 on one or both of their front ends 103, 105 or edge surfaces 117 in a wall section spaced apart from the respective front ends 108, 110. If edge surfaces 117 are produced at a distance from the respective front ends, a cutout 113 is produced in the wall 107 of a respective pipe section 101. The pipe slug that falls out is preferably caught inside the pipe with a collecting container inserted into the first pipe section and removed from the inside of the pipe.

In a further (optional) method step 9a, 9b, the first and second pipe sections 101, 102 are cleaned at the edge surfaces 115, 117. In one embodiment, cleaning takes place by means of a rotationally driven brush or a milling cutter. By cleaning the edge surfaces 115, 117, metal oxides and loose particles or burrs, in particular, which have arisen during plasma cutting to produce the edge surfaces, are to be removed as far as possible. In a next method step 11, the first pipe section 101 and the second pipe section 102 are aligned with one another. When aligning, the edge surfaces 115 of one pipe section 102 are aligned as closely as possible adjacent to the correspondingly designed edge surfaces 117 of the other pipe section 101 in each case. The second pipe section 102 can be aligned manually or by means of the handling device 52 controlled automatically. If the first pipe section 101 has not yet been clamped, the clamping step is now carried out.

In a preferred embodiment, the second tubular 102 is aligned with the clamped first tubular 101 and held by the first handling device 101 until the tubulars 101, 102 are either stapled or fully welded. The stapling is preferably carried out by means of the second handling device 50, which in turn accommodates a corresponding working head for this purpose.

In a subsequent method step 13, the aligned tube sections 101, 102 are welded to one another along the peripheral edge surfaces 115, 117 aligned with one another. With the welding, a completely circumferential weld seam 109 is preferably produced, which has a continuous root extending on the inside of the pipe sections 101 , 102 .

The collecting container with which the pipe slug was also collected, or another collecting container, is preferably used to collect welding spatter. The collection containers are preferably moved under machine control.

After the welding, the pipe sections welded to one another are then prepared in a method step 15 for the subsequent coating. Step 15 includes, for example, the cleaning of the tube sections welded to one another in one or more immersion baths, in which, for example, pickling or rinsing media, such as demineralized water, can be kept available. The exact number and order of operations in this step depends on the specifications of the coating material to be used.

The welded pipe sections 101, 102 prepared in step 15 are chemically coated in a next method step 17 in one or more dips using an autodeposition method. The immersion achieves that the inside, including the weld seam or weld seams 109, but also the outside of the tubular element 100 is essentially completely coated.

Subsequent to the coating—method step 17—of the tube sections 101 , 102 and the weld seam 109 connecting the tube sections with a polymer-based layer 111 , a thermal post-treatment takes place in step 19 . In one configuration of the method, method step 19 can comprise one or more sub-steps, in each of which a flash-off or annealing with predetermined temperatures and annealing times takes place (low annealing or high annealing).

Optionally, the coated and already post-treated pipe elements 100 produced from the pipe sections 101 , 102 can be powder-coated in a method step 21 . Step 21 of powder coating can take place immediately after method step 17 or also after a previously performed thermal after-treatment according to step 19. According to a preferred embodiment of the method, after step 21 of powder coating, a thermal after-treatment according to step 19 is carried out in order to harden the powder coating produced .

Then, in method step 23, the tubular element produced is removed from the manufacturing process and, for example, supplied to intermediate storage.

For the sake of simplicity, method step 19 for thermal post-treatment of the pipeline elements is shown as a single step. In method step 25, the tubular element 100 can be subjected to a number of successive heat treatment stages, which are carried out in one or in a number of different temperature control devices.

The method has been explained schematically with reference to FIG. The tubular element 100 produced with the method, to which reference has already been made, is explained in more detail in FIGS. 2a, 2b. The pipeline element 100 shown in Fig. 2a, 2b comprises a first pipe section 101 and a second pipe section 102.

The first pipe section 101 has a cutout 113 (FIG. 3) in its side wall 107 where it is welded to the second pipe section 102 . In the embodiment shown, the first pipe section 101 and the second pipe section 102 are connected by means of a single-layer weld seam 109 that runs all the way around.

The interior of the tubular element 100 has a polymer-based layer 111 which extends completely along the inner sides of the tubular sections 101 , 102 and also completely covers the circumferential weld seam 109 in the interior of the tubular element 109 . If the pipe element 100 was coated in a dipping process, the outer surface of the pipe element 100 and thus of the first and second pipe section 101 , 102 and the weld seam 109 is at least largely covered by the polymer-based layer.

In the embodiment shown, the second pipe section 102 is arranged approximately centrally between a first front end 108 and a second front end 110 of the first pipe section 101 . In the embodiment shown, the second tube section 102 is aligned coaxially with the wall cutout 113 formed in the side wall 107 of the first tube section 101 . The second pipe section 102 and the first pipe section 101 are aligned with one another at an angle α, which is 90° in the present embodiment.

Depending on the specifications directed to the tube element, the angle α can also range between 30 and 90 degrees. In the embodiment shown in Fig. 2a and 2b, the first pipe section 101 is a base pipe and the second pipe section 102 represents a connection element.

In the present embodiment, the first pipe section 101 has a diameter that differs from the diameter of the second pipe section 102 . The diameters of the first and second pipe sections 101, 102 can also be identical.

The two pipe sections 101, 102 are fixed to one another during the welding, in particular using a clamping device and a handling device, which will be explained in more detail below, in order to ensure a constant gap distance between the pipe sections. This facilitates the creation of a weld seam 109 with complete root coverage of at least the edge surface 115 of the second pipe section 102 or even the edge surfaces 115, 117 of both pipe sections 102, 101. Figures 3a, b show schematic views of a device 30 for producing a polymer-coated pipe element 100 shown by way of example in Figures 2a and 2b. The device 30 comprises a support device 32 with rails 33, along which support parts 34, 35 for receiving the first pipe section 101 can be moved are. In a section between the rails 33, an angle positioner 36 for the first tubular element 101 is arranged.

In one embodiment, the device 30 comprises a first handling device 52 and a second handling device 50, preferably both designed as handling robots, the precise function of which is described in detail below.

In the figures 4 to 9 partial views of the device 30 are shown during various manufacturing steps of the polymer-coated tubular element 100. The device 30 comprises a support device 32 which has two support parts 34, 35 which are set up to receive the front ends 108, 110 of the first pipe section 101. Along a portion of the support means 32 is positioned the angle positioner 36 which is still in a standby position, see Figures 4a, 4b. The handling devices 50, 52 are shown below in abstract form in the drawings for the sake of clarity.

As shown in Figures 5a, b and 6a, b, the angle positioner 36 is then transferred into a working position, namely in a close range to the first pipe section 101 (Fig.5b), with the angle positioner 36 preferably transverse to the rails 33 and thus transverse to the Longitudinal axis of the first tubular element 101 can be moved. The support device 32 moves into a predetermined position with the received first pipe section 101 to the angle positioner 36 such that a section for which a connection area is to be created on the first pipe section 101 is arranged centrally to the angle positioner 36 .

Also, in an embodiment of the present invention, a sacrificial bowl 38 is inserted into the inside of the first tubular portion 101 to the position where the connection portion with the second tubular portion 102 is to be formed. The sacrificial bowl 138 serves in particular to catch residues soiling the inside of the first pipe section, which arise during the subsequent processing of the first and second pipe section 101, 102 and as described in more detail in WO2020/002486A1, for example. As FIGS. 6a, b also show, the first pipe section 101 is then clamped by the angle positioner 36. FIG. The clamping is carried out by means of a clamping device 40 present on the angle positioner 36, which comprises two clamping means 41, 42 which act on the first pipe section 101 on both sides of the connection area to be produced. The clamping devices are designed as 3-point grippers. This ensures that the first pipe section 101 to be picked up is clamped with its central axis almost coaxial to the clamping center of the clamping means 41 , 42 . With the tightening by the angle positioner 36, a previous clamping force applied to the support members can be released, so that the first pipe section

101 is movable at least to certain sections of the support parts 34, 35 of the support device 32.

In a preferred embodiment of the invention, the device 30 has a detection device 44 which is set up to detect a three-dimensional shape at the connection area of at least the first pipe section 101 . The surface of the first pipe section 101 is scanned with the detection device 44 in order to determine tolerances in the form of any out-of-roundness on this section of the pipe section 101 .

The spatial shape in the connection area of the second pipe section 102 is also detected by means of the detection device 44 or a separate detection device, for example a stationary detection device. The second pipe section

102 is gripped by the handling device 52 and positioned.

Using a processing unit 46 coupled to the detection device 44 in a signal-conducting manner, a spatial penetration curve is then determined as a function of a superimposition of the detected spatial shapes of the first and second pipe sections 101, 102, and sectional contours of the first and second pipe sections 101, 102 are determined on the basis of the determined penetration curve.

The cutting contours are transmitted from the computing unit 46 to a cutting device 48, by means of which edge surfaces 115, 117 (FIG. 3) which are coordinated with one another are produced on the first and second pipe sections 101, 102.

In the present embodiment of the device shown in FIGS. 7a, b, the cutting device 48 is designed as a processing attachment for an automatically controlled handling device 50, such as a robot. That In the embodiment shown, the handling device 50 performs all the processing on the first pipe section 101 using appropriate detection and processing attachments of the device. The handling device 50 also welds the first and second pipe section 101 , 102 to form the pipe element 100 by means of a welding attachment.

As can be seen from FIGS. 8a, b, the correspondingly designed pipe section 102 is then aligned with the first pipe section 101 by means of the automated controlled handling device 52.

In a preferred embodiment of the invention, the first and second pipe sections 101, 102 are then welded to one another with a welding device 56, which is preferably arranged as a processing attachment on the handling device 50.

In one embodiment, the pipe sections 101, 102 are welded to one another along the mutually aligned edge surfaces 115, 117. In a preferred embodiment of the invention, the edge surfaces produced during cutting are welded to one another along the determined spatial penetration curve.

A single-layer circumferential weld seam 109 is also preferably produced in the present case. During the entire processing, any processing residues that arise, such as welding spatter, for example, are caught by the sacrificial bowl 38 arranged inside the first pipe section. Any processing preferably takes place on the first pipe section 101 in the trough position. The bottom position means that the processing, regardless of whether it is cutting or welding, takes place from above, so that any processing residues that arise can then fall down into the sacrificial bowl. For this purpose, the first raw section 101 is always rotated into the corresponding angular position.

As can be seen from FIGS. 9a, b, several, two or three such pipe sections 102 can be arranged on a first pipe section 101 at predetermined intervals along its longitudinal axis. The pipe element 100 produced thus has a number of branches on the pipe section 101 .

After the manufacture of such a tubular element 100, the clamping device 40 of the angular positioner 36 is released, as a result of which the tubular section 101 is released. Of the After being released by the clamping means, the angle positioner 36 moves from the working position back into its rest position at a distance from the pipe section 101 .

The clamping means 41, 42 of the clamping device 40 are accommodated on the angle positioner 36 so that they can be moved in particular around a rotation axis 60, in particular along an adjustment device 58. With the movement of the clamping means 41, 42, the first pipe section 101 becomes coaxial around a tool center point (TCP). emotional. The tool center point is formed by the clamping center of the clamping means 41 , 42 of the angular positioner 36 and coincides with the axis of rotation 60 . The more detailed mode of operation of the angle positioner is described below for the embodiment of the angle positioner 36 shown in FIG.

FIG. 10 shows a detailed drawing of the angular positioner 36 in order to explain the functioning and the structure of the clamping device 40 accommodating the first pipe section 101 . The clamping device 40 comprises clamping means 41 , 42 with which the first pipe section 101 is clamped on a rotation axis 60 of the angular positioner 36 on both sides of a connection area on the first pipe section 101 . The axis of rotation 60 also forms the tool center point (TCP), which is used as the starting point for the processing of the first pipe section 101 and the step of welding the first and second pipe sections 101, 102 together, and which preferably serves as a reference axis for the spatial penetration curve .

The clamping means 41 , 42 are moved together with the clamped first pipe section 101 on a circular path around the axis of rotation 60 of the angular positioner 36 . A curved guide 62 is assigned to the first clamping device 40 for each clamping means 41 , 42 . The guide 62 preferably has a rail body 64 in the form of a ring segment.

The clamping means 41 , 42 are arranged on a guide surface 65 facing the axis of rotation 60 for the first pipe section 101 . The clamping means 41 move about their defined clamping center, which coincides with the axis of rotation 60 of the angle positioner and the tool center point (TCP) of the device. The clamping means 41 , 42 are coupled to a drive unit 66 for controlled movement relative to the guide rail 62 . In one embodiment of the device 30 according to the invention, the rail body 64 is designed as a ring segment and extends over an angular range of approximately 180° to approximately 270°, preferably at an angle of approximately 240°. As a result, the first pipe section can be moved in the radial direction in relation to the axis of rotation 60 of the angular positioner 36 , which simplifies the picking up and removal of the first pipe section 101 .

In a further embodiment of the device, it is provided that the adjustment device 58 has a receptacle 68 for each annular guide rail 62, in which the guide rail 62 is located on a guide surface 69 facing away from the axis of rotation 60, thus in addition to the clamping means movably accommodated on the guide rail 62 41 , 42 create a more flexible adjustment option for the first pipe section 101 .

A further drive unit 70 for a controlled movement of the guide rail 62 relative to the receptacle 68 is provided on the receptacle 68 . The guide rail can be moved by more than 90 angular degrees, preferably by more than 180 angular degrees, so that the clamping means can be moved on a full circular path around the axis of rotation 60 despite the accessibility in the radial direction to the angle positioner. The pipe section to be machined can thus be machined over its entire circumference.

The method according to the invention and the device according to the invention are preferably operated under partial or complete computer control. For this purpose, the device 30 preferably has a machine control 72 . The machine control is preferably connected in a signal-conducting manner to the handling devices 50, 52 and the clamping device 40, to the detection, cutting and welding device(s) (if available in addition to the handling devices), the computing unit 46, and more preferably additional peripheral devices such as a collecting device , which controls the collection container for the pipe slug and the welding spatter.

The machine controller 72 may include central control logic or may include one or more sub-controllers. The machine controller 72 can control the various working devices directly or cooperate with the controllers of these devices via appropriate protocols. The machine control is set up to issue control commands for carrying out what is described above Issue method in its preferred embodiments and preferably receive inputs from an operator by means of a man-machine interface. The machine control 72 preferably has a data interface for communication with a storage medium that contains a computer program product, which in turn contains the control commands for executing the method.

Identical or similar components are denoted by the same reference symbols.

After the basic process sequence has already been explained with reference to the above figures, the terminology of the common penetration curve will be explained again with reference to FIG. An idealized pipe element is initially assumed, in which the first pipe section 101 and the second pipe section 102 have an idealized contour KID, in which the two pipe sections 101, 102 are each cylinders.

In reality, however, the first pipe section 100 normally does not have a perfect cylindrical shape, but rather a different shape, which is expressed in the non-cylindrical surface Ki which is subject to tolerances. The area Ki is recorded as a group of points in the method according to the invention. The group of points is characterized either using absolute coordinates or using deviations from the idealized cylindrical shape.

In the same way as the first pipe section 101, the second pipe section 102 does not have an ideal cylindrical shape, but rather a surface K2 that deviates from the ideal cylindrical shape, which is also characterized as a group of points after it has been recorded by measurement.

The common spatial penetration curve D results from the intersection of the two surfaces or groups of points Ki and K2. In other words, those coordinates that are present in both Ki and K2 lie on the common spatial penetration curve.

To prepare the pipe sections 101 and 102 before the welding operation, the cut surfaces are produced by making a recess in the first pipe section 101 along the common penetration curve D, which would correspond to the projection of K2 viewed from above (Fig. 11 bottom left). Into the end of second pipe section 102, a cut surface is introduced which, viewed from the side (Fig. 1 1 top left) corresponds to the projection of Ki. The two pipe sections 101, 102 prepared in this way can then be positioned relative to one another and guided along the common penetration curve D by means of a handling robot. The welding step is most preferably performed in a single continuous motion in which the welder is applied to a location and traverses the common spatial penetration curve D without stopping to complete the weld until the location is reached again. Due to its regularity, the weld seam produced in this way is ideally prepared for the subsequent polymer refinement, both on the outside of the tubular element and on the inside in the area of the weld root.

Reference character list:

1a, b Providing the pipe sections

3a, b Recording the spatial form

5 Determine the spatial penetration curve/intersection contours

7a, b Creation of edge surfaces

9a, b Cleaning the edge surfaces

11 Aligning the Pipe Sections

13 Welding the pipe sections

13.1 Measuring

13.2 Selecting parameters

13.3 Reading in the parameters

13.4 Tacking the pipe sections

15 Preparing the tubular element

17 Coating of the tubular element

19 Aftercare

21 powder coating

23 discharge of the tubular element

30 device

32 support device

33 rails

34, 35 support part

36 angle positioner

38 sacrificial bowl

40 clamping device

41, 42 clamping means

44 detection device

46 unit of account

48 cutter

50, 52 handling device

56 welding device

58 adjusting device

60 axis of rotation/TCP

62 guide rail

64 rail bodies 65 guiding surface

66, 70 drive unit

68 recording

69 guide surface 72 machine control

100 pipe element

102 second pipe section

101 first pipe section 103, 105 front end

107 side wall

108, 110 front end

109 weld

111 Coating 113 Cutout

115, 117 edge faces

Claims

Expectations:

1. A method for the automated or semi-automated production of a polymer-coated tubular element (100), using tube sections (101, 102) that are subject to tolerances, comprising the steps:

- providing a first pipe section (101) and a second pipe section (102), the pipe sections each having a connection region which is provided for connection to the other pipe section in each case;

- determining a spatial penetration curve as a function of a superposition of the spatial shapes,

- determining a cutting contour in the connection area of the first pipe section and a cutting contour in the connection area of the second pipe section, each as a function of the penetration curve;

- Generating edge surfaces (1 15, 117) in the connecting areas of the first and second tube section along the respective cutting contours;

- Aligning the generated edge surfaces of the pipe sections to one another; and

- Welding the first and second pipe sections along the mutually aligned edge surfaces along the determined spatial penetration curve.

2. The method of claim 1, wherein the step of determining the spatial shapes comprises:

- providing an idealized model of the first pipe section and an idealized model of the second pipe section, and

- Determination of deviations of the recorded spatial forms of the pipe sections from their respective model.

3. The method of claim 2, wherein the step of determining the spatial penetration curve comprises:

- providing or generating an idealized penetration curve as a function of the idealized models, and

- Generation of the spatial penetration curve by applying the deviations of the spatial shapes to the idealized penetration curve.

4. The method of claim 1 or 2, wherein the step of determining the spatial shapes comprises:

- Determination of groups of points for both pipe sections, the groups of points lying on the respective surface of the connection areas and characterizing the spatial shape of the pipe sections in the connection areas; and preferably wherein the step of determining the spatial penetration curve comprises:

Forming the spatial penetration curve from the intersection of the sets of points.

5. The method according to any one of the preceding claims, further comprising the step:

- Clamping the first pipe section by means of a clamping device (40), preferably in such a way that the first pipe section is rotatably accommodated about an axis of rotation of the clamping device.

6. Device (30) for the automated or semi-automated production of a polymer-coated tubular element (100) using tube sections (101, 102) subject to tolerances, the tube sections each having a connection region which is intended for connection to the other tube section, the device

- at least one detection device (44) for detecting a spatial shape in each of the connection areas;

- A computing unit (36) which is set up to determine a spatial penetration curve as a function of a superimposition of the detected spatial shapes, and as a function of the penetration curve to determine cutting contours in the connecting areas of the first and second pipe sections (101, 102);

- A cutting device (48) for producing edge surfaces (115, 117) in the connection areas of the first and second pipe sections (101, 102) along the respective cutting contours, and

- A welding device (56), which is adapted to the first and second pipe section (101, 102) along the mutually aligned edge surfaces (1 15, 1 17) along the specific spatial penetration curve to be welded together.

7. The device according to claim 6, with a clamping device (40) for the first pipe section (101) and a handling device (52), in particular a handling robot, for the second pipe section (102).

8. The device according to claim 7, wherein the clamping device (40) comprises at least one clamping means (41, 42) and is set up to rotate the first pipe section (101) about an axis of rotation (60).

9. The device according to claim 8, wherein the clamping means (41, 42) has a clamping center which defines the axis of rotation (60) of the clamping device (40).

10. The device according to claim 8 or 9, wherein the clamping means (41) is a first clamping means, and the clamping device (40) has a second clamping means (42) which is arranged along the axis of rotation (60) at an axial distance from the first clamping means, wherein the clamping device (40) is set up to clamp the first pipe section (101) on both sides of the connection area.

11 . Device according to one of Claims 8 to 10, in which the clamping means or means is/are designed to be open on one side and is/are set up to receive and clamp the first pipe section from above.

12. Device according to one of claims 8 to 11, wherein the (first and/or second) clamping means (41, 42) is set up to fix the first pipe section (101), and wherein the clamping device (40) is set up to to pivot the clamping means (41, 42) in such a way that the first pipe section (101) rotates around the axis of rotation (60).

13. Apparatus according to claim 8 to 12, wherein the clamping means (40) comprises an arcuate guide (62) along which the clamping means is movably received, the guide (62) being concentrically aligned and arranged relative to the axis of rotation (60). to guide the clamping means (41, 42) around the axis of rotation (60).

14. Device according to one of the preceding claims 6 to 13, wherein the handling device (52) is a first handling device, and the device also has a second handling device (50), in particular a handling robot, which has a receptacle for various processing attachments.

15. Device according to one of Claims 6 to 13, with an electronic machine control which is connected in a signal-conducting manner to the detection device, the computing unit, the cutting device, the welding device and preferably one, several or all of the clamping device, the first and/or the second handling device and arranged to carry out the method according to any one of claims 1 to 5.

16. A computer program product comprising instructions which, when the program is executed by a computer, cause the latter to then carry out the steps of the method according to any one of claims 1 to 5.

17. Polymer-coated pipe element (100), with a first pipe section (101) and a second pipe section (102), which are connected to one another by means of a continuous weld seam (109) and at least on the inside of the pipe, but preferably on the inside of the pipe and on the outside of the pipe, are coated with a polymer-based layer (111), wherein the polymer-based layer (111) is chemically bonded to the material of the tubular element, and preferably contains a polymer-based autodeposition material, wherein the tubular element more preferably in a method according to any one of claims 1 to 5 and /or has been produced using a device according to any one of claims 6 to 15.