Flange fitting for tubular structures
Devices, systems, and methods are directed to automated techniques for fitting flanges to tubular sections used to form tubular structures, such as large-scale structures used in industrial applications (e.g., wind towers and pipelines). As compared to manual techniques for fitting flanges to tubular sections, the devices, systems, and methods of the present disclosure facilitate faster attachment of flanges, which may be useful for achieving cost-effective throughput. By way of further comparison to manual techniques, the devices, systems, and methods of the present disclosure may, further or instead, facilitate achieving tighter dimensional tolerances. In turn, such tighter dimensional tolerances may be useful for forming thinner-walled, lighter, and lower cost tubular structures. Still further or in the alternative, automated techniques for fitting flanges to tubular sections may facilitate attachment of multipiece flanges or other non-traditional flange geometries.
1 . A method of fitting a flange to a tubular section, the method comprising:
rotating the tubular section toward a joining unit;
rotating at least one portion of the flange toward the joining unit;
receiving one or more signals indicative of a radial offset between the tubular section and the at least one portion of the flange;
comparing the one or more signals indicative of the radial offset to a target value; and
based at least in part on the comparison of the one or more signals to the target value, adjusting the radial offset between the at least one portion of the flange and the tubular section as the tubular section and the at least one portion of the flange each rotate toward the joining unit, wherein the one or more signals indicative of the radial offset include a radius of curvature of the tubular section between two tube rollers.
2 . The method of claim 1 , wherein rotation of the tubular section and rotation of the at least one portion of the flange are each about an axis perpendicular to a direction of gravity.
3 . The method of claim 1 , wherein, in a radial direction, the at least one portion of the flange is more rigid than the tubular section.
4 . The method of claim 1 , wherein rotating the tubular section includes driving at least one roller in contact with an outer surface of the tubular section.
5 . The method of claim 1 , wherein rotating the at least one portion of the flange toward the joining unit includes engaging first surface of the at least one portion of the flange with a pusher roller, and engaging a second surface of the at least one portion of the flange with a locating roller such that the at least one portion of the flange is pinched between the locating roller and the pusher roller.
6 . The method of claim 1 , wherein the one or more signals indicative of the radial offset are received from one or more sensors as the tubular section and the at least one portion of the flange move toward the joining unit.
7 . The method of claim 1 , wherein the one or more signals indicative of the radial offset include a radial distance between a location on the tubular section and a corresponding circumferential location on the flange.
8 . The method of claim 1 , wherein the one or more signals indicative of the radial offset include a user input.
9 . The method of claim 1 , wherein the at least one portion of the flange is a unitary hoop, and the target value of the radial offset is based on a first circumference of the unitary hoop relative to a second circumference of the tubular section.
10 . The method of claim 1 , wherein the target value varies as the at least one portion of the flange and the tubular section rotate toward the joining unit.
11 . A method of fitting a flange to a tubular section, the method comprising:
rotating the tubular section toward a joining unit;
rotating at least one portion of the flange toward the joining unit;
receiving one or more signals indicative of a radial offset between the tubular section and the at least one portion of the flange;
comparing the one or more signals indicative of the radial offset to a target value; and
based at least in part on the comparison of the one or more signals to the target value, adjusting the radial offset between the at least one portion of the flange and the tubular section as the tubular section and the at least one portion of the flange each rotate toward the joining unit wherein the target value varies as the at least one portion of the flange and the tubular section rotate toward the joining unit, and adjusting the radial offset includes receiving an indication of circumferential spacing between a first tick mark on the tubular section and a second tick mark on the at least one portion of the flange, and adjusting the target value for the radial offset based on the indication of circumferential spacing of the first tick mark relative to the second tick mark.
12 . The method of claim 1 , further comprising adjusting an axial gap between the tubular section and the at least one portion of the flange.
13 . The method of claim 12 , wherein adjusting the axial gap between the tubular section and the at least one portion of the flange includes moving the at least one portion of the flange in an axial direction as the tubular section remains fixed in the axial direction.
14 . The method of claim 1 , further comprising joining the at least one portion of the flange to the tubular section as the tubular section and the at least one portion of the flange rotate toward the joining unit.
15 . The method of claim 11 , wherein rotation of the tubular section and rotation of the at least one portion of the flange are each about an axis perpendicular to a direction of gravity.
16 . The method of claim 11 , wherein, in a radial direction, the at least one portion of the flange is more rigid than the tubular section.
17 . The method of claim 11 , wherein rotating the tubular section includes driving at least one roller in contact with an outer surface of the tubular section.
18 . The method of claim 11 , wherein rotating the at least one portion of the flange toward the joining unit includes engaging first surface of the at least one portion of the flange with a pusher roller, and engaging a second surface of the at least one portion of the flange with a locating roller such that the at least one portion of the flange is pinched between the locating roller and the pusher roller.
19 . The method of claim 11 , wherein the one or more signals indicative of the radial offset are received from one or more sensors as the tubular section and the at least one portion of the flange move toward the joining unit.
20 . The method of claim 11 , wherein the one or more signals indicative of the radial offset include a user input.