GB2576152A - Method and apparatus for forming a flexible tubular element - Google Patents
Method and apparatus for forming a flexible tubular element Download PDFInfo
- Publication number
- GB2576152A GB2576152A GB1812737.3A GB201812737A GB2576152A GB 2576152 A GB2576152 A GB 2576152A GB 201812737 A GB201812737 A GB 201812737A GB 2576152 A GB2576152 A GB 2576152A
- Authority
- GB
- United Kingdom
- Prior art keywords
- helically corrugated
- tubular conduit
- corrugated formation
- forming
- die set
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L55/00—Devices or appurtenances for use in, or in connection with, pipes or pipe systems
- F16L55/02—Energy absorbers; Noise absorbers
- F16L55/033—Noise absorbers
- F16L55/0337—Noise absorbers by means of a flexible connection
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/06—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of tubes or metal hoses; Combined procedures for making tubes, e.g. for making multi-wall tubes
- B21C37/12—Making tubes or metal hoses with helically arranged seams
- B21C37/124—Making tubes or metal hoses with helically arranged seams the tubes having a special shape, e.g. with corrugated wall, flexible tubes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D15/00—Corrugating tubes
- B21D15/04—Corrugating tubes transversely, e.g. helically
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
- F01N13/18—Construction facilitating manufacture, assembly, or disassembly
- F01N13/1805—Fixing exhaust manifolds, exhaust pipes or pipe sections to each other, to engine or to vehicle body
- F01N13/1811—Fixing exhaust manifolds, exhaust pipes or pipe sections to each other, to engine or to vehicle body with means permitting relative movement, e.g. compensation of thermal expansion or vibration
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N13/00—Exhaust or silencing apparatus characterised by constructional features ; Exhaust or silencing apparatus, or parts thereof, having pertinent characteristics not provided for in, or of interest apart from, groups F01N1/00 - F01N5/00, F01N9/00, F01N11/00
- F01N13/18—Construction facilitating manufacture, assembly, or disassembly
- F01N13/1805—Fixing exhaust manifolds, exhaust pipes or pipe sections to each other, to engine or to vehicle body
- F01N13/1811—Fixing exhaust manifolds, exhaust pipes or pipe sections to each other, to engine or to vehicle body with means permitting relative movement, e.g. compensation of thermal expansion or vibration
- F01N13/1816—Fixing exhaust manifolds, exhaust pipes or pipe sections to each other, to engine or to vehicle body with means permitting relative movement, e.g. compensation of thermal expansion or vibration the pipe sections being joined together by flexible tubular elements only, e.g. using bellows or strip-wound pipes
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L11/00—Hoses, i.e. flexible pipes
- F16L11/14—Hoses, i.e. flexible pipes made of rigid material, e.g. metal or hard plastics
- F16L11/15—Hoses, i.e. flexible pipes made of rigid material, e.g. metal or hard plastics corrugated
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L27/00—Adjustable joints, Joints allowing movement
- F16L27/10—Adjustable joints, Joints allowing movement comprising a flexible connection only, e.g. for damping vibrations
- F16L27/107—Adjustable joints, Joints allowing movement comprising a flexible connection only, e.g. for damping vibrations the ends of the pipe being interconnected by a flexible sleeve
- F16L27/11—Adjustable joints, Joints allowing movement comprising a flexible connection only, e.g. for damping vibrations the ends of the pipe being interconnected by a flexible sleeve the sleeve having the form of a bellows with multiple corrugations
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L9/00—Rigid pipes
- F16L9/02—Rigid pipes of metal
- F16L9/06—Corrugated pipes
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N2470/00—Structure or shape of gas passages, pipes or tubes
- F01N2470/12—Tubes being corrugated
Landscapes
- Engineering & Computer Science (AREA)
- General Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Exhaust Silencers (AREA)
Abstract
A flexible tubular conduit 1 has a first helically corrugated formation 6 comprising a right hand helix, and a second helically corrugated formation 7 comprising a left hand helix. A method of forming the flexible tubular element comprises feeding a tubular conduit 8 through a first forming station 10, configured to form the first helically corrugated formation, and through a second forming station 11, configured to form the second helically corrugated formation. The first and second forming stations are controlled selectively to engage and disengage the tubular conduit. Another method of forming the tubular conduit comprises feeding a tubular conduit through a forming station having a reconfigurable die set 14, configuring the die set in a first configuration to form the first helically corrugated formation, and configuring the die set in a second configuration to form the second helically corrugated formation. A vehicle (4, fig 1) comprises an exhaust system (2, fig 1) with the flexible tubular element.
Description
METHOD AND APPARATUS FOR FORMING A FLEXIBLE TUBULAR ELEMENT
TECHNICAL FIELD
The present disclosure relates to a method and apparatus for forming a flexible tubular element. In particular, but not exclusively, the present disclosure relates to a method of forming a flexible tubular element for an exhaust system; and apparatus for forming a flexible tubular element. The present disclosure also relates to a flexible tubular element formed according to the method described herein; an exhaust system comprising one or more flexible tubular element; and a vehicle, such as a motor vehicle.
BACKGROUND
Single sided exhaust systems are subject to strong torsional vibration modes (i.e. twisting about a central longitudinal axis). These loads may necessitate the inclusion of a mass damper to control and reduce vibrations in the exhaust system. This adds significant cost and weight to the exhaust system. These torsional vibrations originate at the internal combustion engine, particularly with north-south mounted engines, where the engine will rock about the axis of the drive shaft leading to the rear wheels. Decouplers have been developed to isolate the exhaust system from the vibration of the engine. However, these decoupler designs are relatively poor at decoupling torsional vibrations. Moreover, known decoupler designs may be structurally weaker in torsion than other vibration modes.
US 7,315,332 B1 discloses a flexible line element having at least two interconnected metal bellows, at least one of which is helically corrugated. The flexible line element is arranged to prevent the transfer of torsional stresses. An arrangement is disclosed having first and second counter-rotating metal bellows. The first and second bellows are formed separately and then joined together to form the flexible tubular element.
At least in certain embodiments, the present invention seeks to provide an improved method and apparatus for fabricating a flexible tubular element.
SUMMARY OF THE INVENTION
Aspects of the present invention relate to a method of forming a flexible tubular element; a flexible tubular element formed according to the method; an exhaust system comprising one or more flexible tubular element; a vehicle; and apparatus for forming a flexible tubular element as claimed in the appended claims.
According to a further aspect of the present invention there is provided a method of forming a flexible tubular element for an exhaust system configured to be connected to an internal combustion engine, the flexible tubular element comprising a first helically corrugated formation and a second helically corrugated formation, the first helically corrugated formation comprising a right hand helix and the second helically corrugated formation comprising a left hand helix, the method comprising:
feeding a tubular conduit through a first forming station and through a second forming station, the first forming station being configured to form the first helically corrugated formation and the second forming station being configured to form the second helically corrugated formation; and controlling the first and second forming stations selectively to engage and disengage the tubular conduit to form said first and second helically corrugated formations in the tubular conduit. The method forms a one-piece flexible tubular element with counter-rotating first and second helically corrugated formations. The first and second helically corrugated formations are formed in the tubular conduit. Thus, the flexible tubular element may be formed from a single piece of tubular conduit. The resulting flexible tubular element has a unitary construction. This avoids the need to join separate tubular members together and, at least in certain embodiments, may provide improved structural integrity.
The first forming station may comprise a first head assembly having a first die set for engaging the tubular conduit; and the second forming station may comprise a second head assembly having a second die set for engaging the tubular conduit. The method may comprise controlling said first head assembly to displace said first die set selectively to engage and/or disengage the tubular conduit; and controlling said second head assembly to displace said second die set selectively to engage and/or disengage the tubular conduit. The first die set and/or the second die set may be advanced to engage; and retracted to disengage. The first head assembly may comprise a first actuator operable selective to engage and/or disengage said first die set. The second head assembly may comprise a second actuator operable selective to engage and/or disengage said second die set.
The first die set may comprise one or more first swaging die. The one or more first swaging die may be oriented at a first angle corresponding to a first helix angle of the first helically corrugated formation. The second die set may comprise one or more second swaging die. The one or more second swaging die may be oriented at a second angle corresponding to a second helix angle of the second helically corrugated formation.
The method may comprise rotating said first head assembly relative to the tubular conduit in a first direction to form the first helically corrugated formation; and rotating said second head assembly relative to the tubular conduit in a second direction to form the second helically corrugated formation. The first and second directions may be opposite to each other. For example, the first direction may be clockwise and the second direction may be counterclockwise. The first and second head assemblies may undergo translation in the same direction as the first and second helically corrugated formations are formed.
In a variant, the method may comprise rotating the first head assembly and the second head assembly relative to the tubular conduit in the same direction. The first and second head assemblies may undergo translation in opposite directions as the first and second helically corrugated formations are formed. The first and second head assemblies may travel towards each other or away from each other as the first and second helically corrugated formations are formed.
The method may comprise controlling the first forming station to engage the tubular conduit to form the first helically corrugated formation while controlling the second forming station to disengage the tubular conduit. Conversely, the method may comprise controlling the second forming station to engage the tubular conduit to form the second helically corrugated formation and controlling the first forming station to disengage the tubular conduit. In an alternative arrangement, the first and second forming stations may be offset from each other in a longitudinal direction such that said first and second helically corrugated formations may be formed simultaneously. The method may comprise controlling said first and second forming stations to engage the tubular conduit at the same time. The method may comprise controlling the first and second forming stations to disengage the tubular conduit and advancing the tubular conduit.
The method may comprise controlling the first and second forming stations to form the first helically corrugated formation and the second helically corrugated formation in a repeating sequence. The repeating sequence may consist of one first helically corrugated formation and one second helically corrugated formation. Alternatively, the repeating sequence may consist of two consecutive first helically corrugated formations and two consecutive second helically corrugated formations.
The method may comprise moving the first and second forming stations and the tubular conduit relative to each other as said first and second helically corrugated formations are formed. The method may comprise moving the first and second forming stations while the tubular conduit remains stationary. The first and second forming stations may be moved together. For example, the first and second forming stations may be mounted on a movable carriage. Alternatively, the first and second forming stations may remain stationary and the tubular conduit may be moved relative thereto.
The method may comprise forming a cylindrical section between said first and second helically corrugated formations. The cylindrical section may facilitate transitioning between said first and second helically corrugated formations. The tubular conduit may subsequently be cut across said cylindrical section to form the flexible tubular element.
In a variant the tubular conduit may be rotated relative to said first and second forming stations.
A continuous section of said tubular conduit may be fed through said first and second forming stations to form one or more of said flexible tubular element. At least in certain embodiments, the tubular conduit is formed into a plurality of flexible tubular elements.
According to a further aspect of the present invention there is provided a method of forming a flexible tubular element for an exhaust system configured to be connected to an internal combustion engine, the flexible tubular element comprising a first helically corrugated formation and a second helically corrugated formation, the first helically corrugated formation comprising a right hand helix and the second helically corrugated formation comprising a left hand helix, the method comprising:
feeding a tubular conduit through a forming station having a re-configurable die set; configuring the re-configurable die set in a first configuration to form the first helically corrugated formation; and configuring the re-configurable die set in a second configuration to form the second helically corrugated formation.
The method may comprise rotating one of the re-configurable die set and the tubular conduit in a first direction to form the first helically corrugated formation; and rotating one of the reconfigurable die set and the tubular conduit in a second direction to form the second helically corrugated formation.
According to a further aspect of the present invention there is provided a flexible tubular element formed according to the method described herein.
According to a still further aspect of the present invention there is provided an exhaust system comprising one or more flexible tubular element as described herein. The one or more flexible tubular element may be provided to decouple at least part of the exhaust system. The one or more flexible tubular element may be incorporated into a decoupler assembly. The decoupler assembly may each comprise a duct disposed inside the flexible tubular element; and/or a protective shield disposed around the flexible tubular element.
According to a further aspect of the present invention there is provided a vehicle comprising an exhaust system as described herein. The exhaust system may be connected to an internal combustion engine provided in the vehicle. The vehicle may, for example, be a motor vehicle.
According to a further aspect of the present invention there is provided an apparatus for forming a tubular conduit into a flexible tubular element for an exhaust system configured to be connected to an internal combustion engine, the flexible tubular element comprising a first helically corrugated formation and a second helically corrugated formation, the first helically corrugated formation comprising a right hand helix and the second helically corrugated formation comprising a left hand helix, the apparatus comprising:
a first forming station for forming the first helically corrugated formation in the tubular conduit;
a second forming station for forming the second helically corrugated formation in the tubular conduit; and a control unit for controlling the first and second forming stations selectively to engage and disengage the tubular conduit to form said first and second helically corrugated formations in the tubular conduit. The control unit is configured to control the first forming station to engage the tubular conduit to form the first helically corrugated formation; and to control the second forming station to engage the tubular conduit to form the second helically corrugated formation.
The first and second forming stations may be arranged coaxially to receive the tubular conduit. The first and second forming stations may be disposed adjacent to each other. In use, the tubular conduit may be fed through said first and second forming stations.
The first forming station may comprise a first head assembly having a first die set for engaging the tubular conduit; and the second forming station may comprise a second head assembly having a second die set for engaging the tubular conduit. The control unit may be configured to control said first head assembly to displace said first die set selectively to engage and/or disengage the tubular conduit; and to control said second head assembly to displace said second die set selectively to engage and/or disengage the tubular conduit.
The first head assembly may be rotatable relative to the tubular conduit in a first direction; and the second head assembly may be rotatable relative to the tubular conduit in a second direction. The first and second directions may be opposite to each other. The first and second head assemblies may be rotatable about a central longitudinal axis of the tubular conduit.
The control unit may be configured to alternate the engagement of the first and second forming stations. For example, the control unit may be configured to control the first forming station to engage the tubular conduit to form the first helically corrugated formation while the second forming station is disengaged. Conversely, the control unit can be configured to control the second forming station to engage the tubular conduit to form the second helically corrugated formation while the first forming station is disengaged. In an alternative arrangement, the first and second forming stations may be offset from each other in a longitudinal direction such that said first and second helically corrugated formations may be formed in the tubular conduit simultaneously. The control unit may be configured to disengage the first and second forming stations after the first and second helically corrugated formations have been formed and the tubular conduit advanced. The simultaneous formation of the first and second helically corrugated formations may help to balance torsional load on the tubular conduit.
The control unit may be configured to control the first and second forming stations to form the first helically corrugated formation and the second helically corrugated formation in a repeating sequence. The repeating sequence may consist of one first helically corrugated formation and one second helically corrugated formation. Alternatively, the repeating sequence may consist of two consecutive first helically corrugated formations and two consecutive second helically corrugated formations.
The first and second forming stations may be movable relative to the tubular conduit. The first and second forming stations may be mounted on a movable carriage. In certain embodiments, the first and second forming stations may be mounted on respective first and second movable carriages. The carriage(s) may be driven by suitable drive means, such as a lead screw. Alternatively, the first and second forming stations may be stationary and the tubular conduit moved relative thereto.
The control unit may be configured to control said first and second forming stations to form a cylindrical section between said first and second helically corrugated formations. The control unit may, for example, control said first and second forming stations to disengage from said tubular conduit to form the cylindrical section.
The control unit may include a processor and a non-transient computer-readable medium for storing data. The processor may be configured to read and/or write data to the non-transient computer-readable medium.
According to a further aspect of the present invention there is provided an apparatus for forming a tubular conduit into a flexible tubular element for an exhaust system configured to be connected to an internal combustion engine, the flexible tubular element comprising a first helically corrugated formation and a second helically corrugated formation, the first helically corrugated formation comprising a right hand helix and the second helically corrugated formation comprising a left hand helix, the apparatus comprising:
a first forming station having a re-configurable die set, the re-configurable die set being configurable in a first configuration to form the first helically corrugated formation and in a second configuration to form the second helically corrugated formation;
a control unit for controlling the first forming station selectively to configure the reconfigurable die set in said first and second configurations to form the first and second helically corrugated formations as the tubular conduit is fed through the first forming station.
The re-configurable die set may be oriented at a first angle corresponding to a first helix angle of the first helically corrugated formation in said first configuration. The re-configurable die set may be oriented at a second angle corresponding to a second helix angle of the second helically corrugated formation in said second configuration.
The control unit may be configured to rotate one of the re-configurable die set and the tubular conduit in a first direction to form the first helically corrugated formation; and to rotate one of the re-configurable die set and the tubular conduit in a second direction to form the second helically corrugated formation.
Alternatively, the relative longitudinal movement of the tubular conduit and the head assembly may be reversed to form said first and second helically corrugated formations. In this arrangement the re-configurable die set and the tubular conduit may rotate in the same direction while said first and second helically corrugated formations are formed.
The re-configurable die set may comprise one or more swaging die.
According to a further aspect of the present invention there is provided a non-transitory, computer-readable storage medium storing instructions thereon that when executed by one or more electronic processors causes the one or more electronic processors to carry out the method described herein.
Any control unit or controller described herein may suitably comprise a computational device having one or more electronic processors. The system may comprise a single control unit or electronic controller or alternatively different functions of the controller may be embodied in, or hosted in, different control units or controllers. As used herein the term “controller” or “control unit” will be understood to include both a single control unit or controller and a plurality of control units or controllers collectively operating to provide any stated control functionality. To configure a controller or control unit, a suitable set of instructions may be provided which, when executed, cause said control unit or computational device to implement the control techniques specified herein. The set of instructions may suitably be embedded in said one or more electronic processors. Alternatively, the set of instructions may be provided as software saved on one or more memory associated with said controller to be executed on said computational device. The control unit or controller may be implemented in software run on one or more processors. One or more other control unit or controller may be implemented in software run on one or more processors, optionally the same one or more processors as the first controller. Other suitable arrangements may also be used.
Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.
BRIEF DESCRIPTION OF THE DRAWINGS
One or more embodiments of the present invention will now be described, by way of example only, with reference to the accompanying figures, in which:
Figure 1 shows a schematic representation of a vehicle incorporating an exhaust system having a flexible tubular element;
Figure 2 shows a longitudinal sectional view of the flexible tubular element shown in
Figure 1;
Figure 3 shows a schematic representation of apparatus suitable for fabricating the flexible tubular element shown in Figure 2;
Figure 4 shows a schematic representation of a forming station having external dies for engaging the tubular conduit to form a helically corrugated formation;
Figure 5 shows a schematic representation of a modified embodiment of the forming station incorporating internal and external dies for engaging the tubular conduit; and
Figure 6 shows a schematic representation of an alternative apparatus suitable for fabricating the flexible tubular element shown in Figure 2.
DETAILED DESCRIPTION
A method and apparatus for forming a flexible tubular element 1 in accordance with an aspect of the present invention will now be described. As shown schematically in figure 1, the flexible tubular element 1 is incorporated into an exhaust system 2 connected to an internal combustion engine 3 in a motor vehicle 4, such as an automobile.
The exhaust system 2 comprises an exhaust passageway for conveying exhaust gases from the internal combustion engine 3. The flexible tubular element 1 comprises a hollow tube. The flexible tubular element 1 is configured to absorb movements and/or vibrations, thereby helping to reduce noise and vibrations. The flexible tubular element 1 may, for example, help to isolate components of the exhaust system 2 from vibrations originating from the internal combustion engine 3. In the present embodiment, the flexible tubular element 1 is incorporated into a decoupling assembly 5, as shown in Figure 2. The decoupling assembly 5 is disposed in the exhaust system 2 and, in use, exhaust gases from the internal combustion engine 3 pass through the flexible tubular element 1.
As shown in Figure 2, the flexible tubular element 1 comprises a first helically corrugated formation 6 and a second helically corrugated formation 7. The first and second helically corrugated formations 6, 7 have different chiralities. The first helically corrugated formation 6 comprises a right hand helix; and the second helically corrugated formation 7 comprises a left hand helix. The first helically corrugated formation 6 has a first helix angle a1; and the second helically corrugated formation 7 has a second helix angle a2. In the present embodiment, the first and second helix angles cd, a2 are the same. In other applications, the first and second helix angles cd, a2 may be different from each other. The flexible tubular element 1 has a unitary construction and is formed from a tubular conduit 8 having a central longitudinal axis X1. The tubular conduit 8 is hollow and has a substantially uniform circular cross-section. The tubular conduit 8 has a diameter of 90mm and is formed from a metal or a metal alloy, such as AISI 321 or AISI 329, having a thickness/gauge of 0.8mm. The central longitudinal axis X1 is a common centreline of both the first and second helically corrugated formations 6, 7. The method and apparatus for fabricating the flexible tubular element 1 from the tubular conduit 8 will now be described with reference to Figure 3.
A forming apparatus 9 for forming the flexible tubular element 1 from the tubular conduit 8 is illustrated in Figures 3 and 4. The forming apparatus 9 comprises a first forming station 10 and a second forming station 11. The first and second forming stations 10,11 and the tubular conduit 8 are movable relative to each other. In the present embodiment, the first and second forming stations 10, 11 are mounted to a movable carriage 12 and arranged to undergo translation in an axial direction parallel to the central longitudinal axis X1. The tubular conduit 8 is centred and held in a fixed position by a chuck (not shown) or other mechanical holding means. As outlined above, the first and second helix angles a1, a2 are the same and the carriage 12 moves at a constant speed relative to the tubular conduit 8. In a variant, the tubular conduit 8 may be arranged to translate relative to the first and second forming stations 10, 11. The first and second forming station 10, 11 will now be described in more detail.
The first forming station 10 comprises a first head assembly 13 having a first die set 14 for engaging the tubular conduit 8 to form the first helically corrugated formation 6. The first die set 14 is adapted to engage an exterior of the tubular conduit 8, as illustrated in Figure 4. The first die set 14 comprises three (3) first swaging dies 17 arranged in a first transverse plane P1 perpendicular to the central longitudinal axis X1. The first swaging dies 17 are angularly offset from each other by 120° in said first transverse plane P1. The first swaging dies 17 have an external profile for forming the first helically corrugated formation 6. The first swaging dies 17 may, for example, comprise rollers. The first swaging dies 17 are oriented at an acute angle relative to the central longitudinal axis X1 corresponding to the first helix angle al.The first swaging dies 17 are movable to selectively engage/disengage the tubular conduit 8. In particular, the first swaging dies 17 are displaced radially inwardly to engage the tubular conduit 8; and displaced radially outwardly to disengage the tubular conduit 8. The first head assembly 13 is rotatable in a first direction about the central longitudinal axis X1, as illustrated by the arrow A1 in Figure 4. By displacing the first swaging dies 17 radially inwardly to engage the tubular conduit 8 while the first head assembly 13 is rotating, the first forming station 10 is operative to form the first helically corrugated formation 6 on said tubular conduit 8.
The second forming station 11 comprises a second head assembly 18 having a second die set 19 for engaging the tubular conduit 8 to form the second helically corrugated formation 7.
The second die set 19 is adapted to engage an exterior of the tubular conduit 8. The second die set 19 comprises three (3) second swaging dies 22 arranged in a second transverse plane P2 perpendicular to the central longitudinal axis X1. The second swaging dies 22 are angularly offset from each other by 120° in the said second transverse plane P2. The second swaging dies 22 have an external profile for forming the second helically corrugated formation 7. The second swaging dies 22 may, for example, comprise rollers. The second swaging dies 22 are oriented at an acute angle relative to the central longitudinal axis X1 corresponding to the second helix angle a2. The second swaging dies 22 are movable to selectively engage/disengage the tubular conduit 8. In particular, the second swaging dies 22 are displaced radially inwardly to engage the tubular conduit 8; and displaced radially outwardly to disengage the tubular conduit 8. The second head assembly 18 is rotatable in a second direction about the central longitudinal axis X1. By displacing the second swaging dies 22 radially inwardly to engage the tubular conduit 8 while the second head assembly 18 is rotating, the second forming station 11 is operative to form the second helically corrugated formation 7 on said tubular conduit 8.
As outlined above, the first helically corrugated formation 6 comprises a right hand helix; and the second helically corrugated formation 7 comprises a left hand helix. The first and second helically corrugated formations 6, 7 are formed by rotating the first and second head assemblies 13, 18 in said first and second directions as the carriage 12 translates relative to the tubular conduit 8. The first and second directions are opposite to each other to form the left and right handed helices forming the first and second helically corrugated formations 6, 7. The first and second head assemblies 13,18 are controlled selectively to engage the first and second swaging dies 17, 22 to form the first and second helically corrugated formations 6, 7. By controlling the first and second swaging dies 17, 22, the first and second helically corrugated formations 6, 7 may be formed in a repeating sequence as the carriage 12 translates along the length of the tubular conduit 8. In the present embodiment, the first and second swaging dies 17, 22 are controlled to engage the tubular conduit 8 in an alternating sequence such that said first and second helically corrugated formations 6, 7 are formed alternately along the length of the tubular conduit 8. The first and second swaging dies 17, 22 may be controlled such that a section of the tubular conduit 8 remains at least substantially un-deformed between the first and second helically corrugated formations 6, 7 to form a cylindrical section 23. However, at least in certain embodiments, the length of the spacer section 23 may be minimised to facilitate packaging of the flexible tubular element 1 in the exhaust system 2.
After forming the first and second helically corrugated formations 6, 7, the tubular conduit 8 is removed from the forming apparatus 9 with the first and second helically corrugated formations 6, 7 formed therein. A cutting apparatus 24 is provided to cut the tubular conduit 8 into sections to form the flexible tubular element 1. The cutting apparatus 24 is configured to cut the tubular conduit 8 in the cylindrical sections 23 formed between the first and second helically corrugated formations 6, 7. The opposing ends of the flexible tubular element 1 may comprise a cylindrical section to facilitate coupling to the adjacent sections of the exhaust system 2.
The forming apparatus 9 comprises a control unit 25 comprising an electronic processor 26 and system memory 27 for controlling operation of the first and second forming stations 10, 11. In particular, the control unit 25 is configured to control the rotational speed of the first and second forming stations 10, 11 relative to the tubular conduit 8 and also selectively to engage/disengage the first and second swaging dies 17, 22. The control unit 25 may, for example, be configured to control operation of first and second actuators (not shown) disposed in the first and second forming stations 10, 11 selectively to engage/disengage the first and second swaging dies 17, 22. The control unit 25 may also be configured to adjust the angular orientation of the first and second swaging dies 17, 22. The control unit 25 may optionally also be configured to control the cutting apparatus 24.
The engagement and disengagement of the first and second swaging dies 17, 22 may be controlled progressively such that the first and second helically corrugated formations 6, 7 have a lead-in portion in which the depth of the helical corrugations increase progressively; and/or a lead-out portion in which the depth of the helical corrugations decrease progressively. The depth of the corrugations in any such lead-in portion or lead-out portion may change progressively. This control strategy may help to reduce torsional load on the tubular conduit 8 during the forming process. In a further variant, the depth of the corrugations may be controlled to taper the first helically corrugated formation 6 and/or the second helically corrugated formation 7 along its length. The first helically corrugated formation 6 and/or the second helically corrugated formation 7 may be tapered inwardly or outwardly.
In the present embodiment the flexible tubular element 1 is incorporated into a decoupling assembly 5, as shown in Figure 2. A protective sleeve, such as a braided metal collar, may be provided around the outside of the flexible tubular element. Alternatively, or in addition, an internal conduit may be disposed inside the flexible tubular element. In the present embodiment, a metal hose 28 is provided inside the flexible tubular element 1; and a protective wire mesh 29 is provided around the outside of the flexible tubular element 1. The metal hose 28 and the protective wire mesh 29 may be connected to the flexible tubular element 1 using suitable mechanical fasteners or fixing techniques, such as welding. One or more liner(s) may be disposed inside the flexible tubular element.
The first and second forming stations 10, 11 have been described herein as comprising first and second swaging dies 17, 22 arranged to engage an exterior of the tubular conduit 8. In a modified arrangement, the first and second swaging dies 17, 22 may be modified to incorporate internal dies for engaging an interior of the tubular conduit 8. A schematic representation of the first forming station 10 incorporating first swaging dies 17 disposed internally and externally of the tubular conduit 8 is shown schematically in Figure 5.
In use, the flexible tubular element 1 is operable at least partially to decouple the exhaust system 2. The flexible tubular element 1 is particularly effective in inhibiting the transmission of torsional vibrations. The arrangement of the first and second helically corrugated formations 6, 7 is such that the axial length of the flexible tubular element 1 (along the central longitudinal axis X1) is substantially unchanged when a torsional load is applied. The torsional load will tend to increase the length of one of said first and second helically corrugated formations 6, 7 and decrease the length of the other one of said first and second helically corrugated formations 6, 7. Thus, the total length of the flexible tubular element 1 will be substantially unchanged.
The method and apparatus described herein utilises first and second head assemblies 13, 18. In a modified embodiment, a single head assembly may be used to form said first and second helically corrugated formations 6, 7 from a pre-formed tubular conduit 8. A forming apparatus 9 having a single forming station 10 is shown schematically in Figure 6. The forming apparatus 9 is a modification of the embodiment described herein with reference to Figure 3. Like reference numerals are used for like components.
The forming station 10 comprises a reversible head assembly 13 having a re-configurable die set 14. The re-configurable die set 14 comprises re-configurable swaging dies 17. In the present embodiment, the re-configurable swaging dies 17 are external dies for engaging an exterior of the tubular conduit 8. The re-configurable swaging dies 17 may be configured in a first configuration to form the first helically corrugated formation 6; and in a second configuration to form the second helically corrugated formation 7. The rotational direction of the head assembly 13 is reversed to form the first and second helically corrugated formations 6, 7. In particular, the head assembly 13 is rotated in a first direction to form the first helically corrugated formation 6; and in a second direction to form the second helically corrugated formations 7. The first direction is opposite to the second direction to form the counter-rotating helical corrugations. The forming apparatus 9 comprises a control unit 25 for controlling the first forming station 10 selectively to re-configure the re-configurable swaging dies 17 and to control the rotation of the head assembly 13.
The control unit 25 controls the re-configurable swaging dies 17 selectively to engage the tubular conduit 8 as it translates through the forming station 10 along the central longitudinal axis X1. In the present embodiment arrangement, the tubular conduit 8 does not rotate as it is fed through the forming station 10. The re-configurable swaging dies 17 are configured in said first configuration and the head assembly 13 rotated in a first direction. The re-configurable swaging dies 17 are selectively controlled to engage the tubular conduit 8 and form the first helically corrugated formation 6. Once the first helically corrugated formation 7 is formed, the re-configurable swaging dies 17 are disengaged from the tubular conduit 8 and re-configured in said second configuration. The rotational direction of the head assembly 13 is then reversed so as to rotate in a second direction. The re-configurable swaging dies 17 are selectively controlled to engage the tubular conduit 8 and to form the second helically corrugated formation 7. Once the first helically corrugated formation 7 is formed, the re-configurable swaging dies 17 are disengaged from the tubular conduit 8. This process is repeated along the length of the tubular conduit 8 to form a sequence of first and second helically corrugated formations 6, 7. The tubular conduit 8 is then cut into lengths to form a plurality of flexible tubular elements 1. The re-configurable swaging dies 17 may be reconfigured by changing their orientation relative to the longitudinal axis X1. In said first configuration, the reconfigurable swaging dies 17 may be oriented at a first angle corresponding to said first helix angle cri. In said second configuration, the re-configurable swaging dies 17 may be oriented at a second angle corresponding to said second helix angle a2.
In an alternative arrangement, the re-configurable die set 14 may comprise first and second sub-sets of the swaging dies 17. The re-configurable die set 14 is re-configured by selectively engaging the first sub-set of the swaging dies 17 or the second sub-set of the swaging dies
17. The first sub-set of said swaging dies 17 may have a first orientation relative to the longitudinal X1 to form the first helically corrugated formation 6; and the second sub-set of said swaging dies 17 may have a second orientation relative to the longitudinal X1 to form the second helically corrugated formation 7. The control unit 25 may be configured selectively to engage first and second sub-sets of said swaging dies 17 to form the first and second helically corrugated formations 6, 7 respectively. The rotational direction of the head assembly 13 may be reversed depending on which sub-set of said swaging dies 17 is operative. The head assembly 13 may be rotated in a first direction to form the first helically corrugated formation 6; and rotated in a second direction to form the second helically corrugated formation 7.
Alternatively, the relative longitudinal movement of the tubular conduit 8 and the head assembly 13 along said longitudinal axis X1 may be reversed depending on which of said first and second sub-sets of the swaging dies 17 is engaged.
It will be appreciated that various modifications may be made to the embodiment(s) described herein without departing from the scope of the appended claims.
The fabrication of the flexible tubular element 1 is described herein as comprising forming left and right helices alternatively along the length of the tubular conduit 8 (each separated by a cylindrical section 23). The control strategy may be modified to form the left and right handed helices in alternating pairs such that two (2) of said left helices are formed sequentially (separated by a cylindrical section 23) and then two (2) of said right helices are formed sequentially (again, separated by a cylindrical section 23). The subsequent cutting operation may be modified such that each flexible tubular element 1 cut from the tubular conduit 8 comprises left and right helices which form the first and second helically corrugated formations 6, 7.
In a variant of the methods described herein, rather than rotate the first forming station 10 and/or the second forming station 11, the tubular conduit 8 may be rotated.
Claims (25)
1. A method of forming a flexible tubular element for an exhaust system configured to be connected to an internal combustion engine, the flexible tubular element comprising a first helically corrugated formation and a second helically corrugated formation, the first helically corrugated formation comprising a right hand helix and the second helically corrugated formation comprising a left hand helix, the method comprising:
feeding a tubular conduit through a first forming station and through a second forming station, the first forming station being configured to form the first helically corrugated formation and the second forming station being configured to form the second helically corrugated formation; and controlling the first and second forming stations selectively to engage and disengage the tubular conduit to form said first and second helically corrugated formations in the tubular conduit.
2. A method as claimed in claim 1, wherein said first forming station comprises a first head assembly having a first die set for engaging the tubular conduit; and the second forming station comprises a second head assembly having a second die set for engaging the tubular conduit.
3. A method as claimed in claim 2, the method comprising controlling said first head assembly to displace said first die set selectively to engage and/or disengage the tubular conduit; and controlling said second head assembly to displace said second die set selectively to engage and/or disengage the tubular conduit.
4. A method as claimed in claim 2 or claim 3 comprising rotating said first head assembly relative to the tubular conduit in a first direction to form the first helically corrugated formation; and rotating said second head assembly relative to the tubular conduit in a second direction to form the second helically corrugated formation; the first and second directions being opposite to each other.
5. A method as claimed in any one of claims 1 to 4 comprising controlling the first and second forming stations to form the first helically corrugated formation and the second helically corrugated formation in a repeating sequence.
6. A method as claimed in claim 5, wherein said repeating sequence consists of one first helically corrugated formation and one second helically corrugated formation or two consecutive first helically corrugated formations and two consecutive second helically corrugated formations.
7. A method as claimed in any one of the preceding claims comprising moving the first and second forming stations and the tubular conduit relative to each other as said first and second helically corrugated formations are formed.
8. A method as claimed in any one of the preceding claims comprising forming a cylindrical section between said first and second helically corrugated formations.
9. A method as claimed in any one of the preceding claims, wherein a continuous section of said tubular conduit is fed through said first and second forming stations to form one or more of said flexible tubular element.
10. A method of forming a flexible tubular element for an exhaust system configured to be connected to an internal combustion engine, the flexible tubular element comprising a first helically corrugated formation and a second helically corrugated formation, the first helically corrugated formation comprising a right hand helix and the second helically corrugated formation comprising a left hand helix, the method comprising:
feeding a tubular conduit through a forming station having a re-configurable die set; configuring the re-configurable die set in a first configuration to form the first helically corrugated formation; and configuring the re-configurable die set in a second configuration to form the second helically corrugated formation.
11. A method as claimed in claim 10, wherein the method comprises:
rotating one of the re-configurable die set and the tubular conduit in a first direction to form the first helically corrugated formation; and rotating one of the re-configurable die set and the tubular conduit in a second direction to form the second helically corrugated formation.
12. A flexible tubular element formed using the method claimed in any one of the preceding claims.
13. An exhaust system comprising one or more flexible tubular element as claimed in claim 11.
14.
A vehicle comprising an exhaust system as claimed in claimed in claim 13.
15. Apparatus for forming a tubular conduit into a flexible tubular element for an exhaust system configured to be connected to an internal combustion engine, the flexible tubular element comprising a first helically corrugated formation and a second helically corrugated formation, the first helically corrugated formation comprising a right hand helix and the second helically corrugated formation comprising a left hand helix, the apparatus comprising:
a first forming station for forming the first helically corrugated formation in the tubular conduit;
a second forming station for forming the second helically corrugated formation in the tubular conduit; and a control unit for controlling the first and second forming stations selectively to engage and disengage the tubular conduit to form said first and second helically corrugated formations in the tubular conduit.
16. Apparatus as claimed in claim 15, wherein said first forming station comprises a first head assembly having a first die set for engaging the tubular conduit; and the second forming station comprises a second head assembly having a second die set for engaging the tubular conduit.
17. Apparatus as claimed in claim 16, wherein the control unit is configured to control said first head assembly to displace said first die set selectively to engage and/or disengage the tubular conduit; and to control said second head assembly to displace said second die set selectively to engage and/or disengage the tubular conduit.
18. Apparatus as claimed in claim 16 or claim 17, wherein said first head assembly is rotatable relative to the tubular conduit in a first direction; and said second head assembly is rotatable relative to the tubular conduit in a second direction; the first and second directions being opposite to each other.
19. Apparatus as claimed in any one of claims 15 to 18, wherein the control unit is configured to control the first and second forming stations to form the first helically corrugated formation and the second helically corrugated formation in a repeating sequence.
20. Apparatus as claimed in claim 19, wherein said repeating sequence consists of one first helically corrugated formation and one second helically corrugated formation or two consecutive first helically corrugated formations and two consecutive second helically corrugated formations.
21. Apparatus as claimed in any one of claims 15 to 20, wherein said first and second forming stations are movable relative to the tubular conduit and optionally wherein said first and second forming stations are mounted on a movable carriage.
22. Apparatus as claimed in any one of claims 15 to 21, wherein the control unit is configured to control said first and second forming stations to form a cylindrical section between said first and second helically corrugated formations.
23. Apparatus for forming a tubular conduit into a flexible tubular element for an exhaust system configured to be connected to an internal combustion engine, the flexible tubular element comprising a first helically corrugated formation and a second helically corrugated formation, the first helically corrugated formation comprising a right hand helix and the second helically corrugated formation comprising a left hand helix, the apparatus comprising:
a first forming station having a re-configurable die set, the re-configurable die set being configurable in a first configuration to form the first helically corrugated formation and in a second configuration to form the second helically corrugated formation;
a control unit for controlling the first forming station selectively to configure the reconfigurable die set in said first and second configurations to form the first and second helically corrugated formations as the tubular conduit is fed through the first forming station.
24. Apparatus as claimed in claim 15, wherein the control unit is configured to rotate one of the re-configurable die set and the tubular conduit in a first direction to form the first helically corrugated formation; and to rotate one of the re-configurable die set and the tubular conduit in a second direction to form the second helically corrugated formation.
25. A non-transitory, computer-readable storage medium storing instructions thereon that when executed by one or more electronic processors causes the one or more electronic processors to carry out the method claimed in any of claims 1 to 11.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB2111655.3A GB2594427B (en) | 2018-08-06 | 2018-08-06 | Method and apparatus for forming a flexible tubular element |
GB1812737.3A GB2576152B (en) | 2018-08-06 | 2018-08-06 | Forming a flexible tubular conduit with helically corrugated formations for an exhaust system |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1812737.3A GB2576152B (en) | 2018-08-06 | 2018-08-06 | Forming a flexible tubular conduit with helically corrugated formations for an exhaust system |
Publications (3)
Publication Number | Publication Date |
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GB201812737D0 GB201812737D0 (en) | 2018-09-19 |
GB2576152A true GB2576152A (en) | 2020-02-12 |
GB2576152B GB2576152B (en) | 2021-09-22 |
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GB1812737.3A Active GB2576152B (en) | 2018-08-06 | 2018-08-06 | Forming a flexible tubular conduit with helically corrugated formations for an exhaust system |
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Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1088559A (en) * | 1963-10-15 | 1967-10-25 | Chester Markmann Heller | Torsional pipe coupling |
US6315332B1 (en) * | 1998-05-29 | 2001-11-13 | Iwk Regler Und Kompensatoren Gmbh | Flexible line element |
-
2018
- 2018-08-06 GB GB1812737.3A patent/GB2576152B/en active Active
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1088559A (en) * | 1963-10-15 | 1967-10-25 | Chester Markmann Heller | Torsional pipe coupling |
US6315332B1 (en) * | 1998-05-29 | 2001-11-13 | Iwk Regler Und Kompensatoren Gmbh | Flexible line element |
Also Published As
Publication number | Publication date |
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GB2576152B (en) | 2021-09-22 |
GB201812737D0 (en) | 2018-09-19 |
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