Laser-based sizing of pipes

Targeted sizing

When pipes are not perfectly round at their ends, hydraulic expanders are used to adjust the roundness. A hydraulic cylinder in the expanders actuates the forming tools which press against the inside surface of the pipe wall to achieve a specific plastic deformation of the pipe.

Where and to which degree exactly the pipe should be deformed used to be difficult to determine due to the lack of suitable measuring data.

Therefore, the PIPE SIZER has an integrated 360° laser measuring system. This laser measures the inside geometry of the pipe in real time, while the software calculates the parameters that ensure high precision control of the sizing process.

The demands on the quality of pipes – especially for perfect roundness – have become increasingly exacting during the last few years, presenting pipe manufacturers with ever new challenges.

MARLON PFEIFER, Project Management

Integrated laser

The pipe sizing tool with up to six forming segments is located at the end of a roller table carrying the pipe. The 360° laser measuring system mounted at the tip of the tool measures the inside contour of the pipe.

Sizing instead of expanding

The pipe sizing tool is inserted into the pipe. At the same time, the 360° laser measures the geometry of the inner pipe wall. From these measurements, the software calculates the actuation values for each one of the six forming segments of the tool.

Depending on the machine model, the individual spreading segments can be extended individually depending on travel and pressure, in order to achieve the desired contour. Upon completion of the first sizing cycle, the pipe is measured again. Based on the newly measured contour values, the software determines the backspring of the pipe material. Then the software calculates the values for the second sizing cycle, taking the backspring into account. This guarantees that the sizing process is adjusted to the specific materials properties of each individual pipe.

Each one of the six forming segments covers a sector of 60°. It may happen that the contour measurements show that the pipe wall needs to be sized at a point located in between two adjacent segments. In this case the pipe sizing tool can be turned into the right position.

High precision inline measurement

The 360° laser measuring system arranged at the tip of the pipe sizing tool measures the inside pipe contour in a non-contact process in real time, generating a complete 2D image of the pipe’s interior.

The measuring system works on the principle of laser triangulation: a laser mounted to the tip of the measuring lance projects a line onto the pipe’s inside wall surface. Two cameras contained in the measuring head capture the projected line at 1080 points distributed over the complete circumference of the inner pipe wall.

The laser measuring system ensures maximum repeatability and gapless documentation of the process.

GMS-I MEASURING SYSTEM

Targeted sizing

Depending on the geometry of the pipe the forming segments of the PIPE SIZER are being actuated and spred apart by hydraulic cylinders. The segments can be moved outwards against the pipe wall separately or all six at a time. Depending on the machine type two opposite segments or three segments arranged at 120° from each other are actuated simultaneously. Expanding with a total of six expansion segments is also possible.

Versatile software

The software for the PIPE SIZER has been specifically tailored to the requirements of the tube and pipe industry. 

Basic software 

Even in its basic version, the software covers a very wide and diverse range of applications. All the features – automatic centerpoint correction and adaptation of the laser to specific surface characteristics of the inside pipe wall, for example – can be adapted to meet the requirements of the tasks on hand.

The basic software includes a wide range of advanced control features – target diameter, minimum and maximum diameter, ovality and automatic centerpoint correction – and a reporting function.

3D visualization

The basic software visualizes the pipe geometry as a 2D contour. In connection with a position measuring gauge, the system generates 3D images of the complete pipe.

Customized software

Our application engineers will customize the software to integrate special features, such as the masking out of welds, to meet any requirements of the task. 

Data export made easy

The pipe geometry data is available in digital form and ready to be used by the operator for the optimization of internal processes via data export to higher level systems.