TPT September 2010

B ending & E nd F orming

Bending simulation and interference testing which at least reduces the danger of damage to the machine. However, he still has to find a way to fabricate the tube, which can be time-consuming and expensive.

BUILDING a pipeline system, for water, oil or any other medium, is a task that involves multiple departments and people. One department creates the initial P&I diagrams, where all systems are outlined, the materials are classified, and the general structure of the system is determined. Another department then uses these P&I diagrams to create isometric drawings or 3D models of the system, which can be divided into spools for fabrication. The tube shop finally has the task of fabricating these spools, a process that often involves bending the tube at certain angles. Unfortunately there are some tubes that even the most experienced operator with the most modern bending machine cannot bend without difficulty, especially if bends are too close together, or would cause the tube to collide with the machine. Designers often have only a vague understanding of the technical limitations of the machines, and so there is a risk that they will design tubes that simply cannot be fabricated, or only by making major adjustments to the bending process. Often an experienced bender can spot these tubes just by looking at the worksheet,

model and machine model it is easy to integrate new tools into the software at a later point. 3R software solutions has included a wide range of additional features, such as IGES-import, creation of segment bends and tube coils, or an approximation of the cycle time. RONIKolli7 is in use worldwide, by shipyards, plant designers, automotive suppliers, and many other businesses working with tubes. 3R software solutions – Germany Fax: +49 2381 9724 711 Email: info@3-r.de Website: www.3-r.de

It isherethatbendingsimulationsoftware, such as RONIKolli7, becomes a powerful tool for both designers and operators. Using virtual models of the machine and its environment the tube geometry is tested for collision. The bending process is simulated graphically, so the collision points can be detected immediately. If a collision is detected the software automatically looks for alternative ways to bend the tube, based on the capabilities of the machine. This may include reversal of the rotation direction, reversal of the bending sequence (last point first), a correction feed, or any combination of these steps. On more sophisticated machines a change of bending level or of the bending direction (left-bending vs right-bending) might solve the problem. If a bending sequence capable of fabricating the tube without collision is found, the CNC data is automatically adjusted, so there is no need for lengthy manual calculations. If a material master file has been created with the K7-MaterialManager RONIKolli7 also adjusts this data for overbending and traction reduction, to compensate for springback. The software can be used either directly at the machine, to test the tubes sent by the construction department, or in that department itself. The designer can immediately check if the iso he is creating can actually be built, and adjust his work accordingly if fabrication is impossible. This saves time and material later in the workshop, and since RONIKolli7 can run in the background it only takes moments to check each spool. The machine models are created on-site by measuring the physical machines, which makes it possible to include any modi- fications or adjustments that distinguish the machine from other models. Since 3R software solutions works with many manufacturers of bending machines, it is often possible to measure the machines prior to delivery, so there is no disruption of the workflow once the machine has arrived on site. Tool models are created by measurement or based on technical drawings, so that only the tools actually used in the workshop are available. Multi-level or multi-stack tools can be created in a few minutes, and each tool can be assigned to multiple machines if required. Due to the separation of tool

RONIKolli7 screenshots

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S eptember 2010

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