TPT November 2010

T echnology U pdate

Improving tube shop efficiency

respect to tool changeover, to reduce the time spent on this task. And since each spool is assigned a unique number, the status of every single component can be monitored at any point during the fabrication process. This way it is possible to analyse machine utilisation, work flow and capacities. While each application developed by 3R software solutions can be used as a standalone product, the combination of RONIIsoBuilder and RAMP can increase a tube shop’s efficiency significantly. Controlling the flow of material and the utilisation of the various machines is another important factor, reducing idle time at the machines and increasing output. But in addition to these four core applications that govern the important tasks involved in designing and fabricating tubes, 3R software solutions also offers various other applications designed to facilitate various processes: Like every other component of a mechanical system, pipes break down over time. Whether due to impact damage or simple corrosion, eventually a part of the pipeline system will have to be replaced. Here it becomes important to fabricate a replacement that can be inserted into the existing system precisely. If the original data used to fabricate the spool is no longer available, it becomes necessary to measure the tube. There are several methods of measuring tube elements, ranging from optical measurementwithmultiplecamerastocontact or non-contact measuring with movable arms. While RONIKolli7 offers import interfaces to many of these systems, 3R software solutions also offers an affordable measuring system of their own with RONITubeFit. The measured data can be transferred to RONIKolli7 in order to calculate the required CNC-data for fabrication. Creating drawings of existing pipeline systems is a task that often has to be performed in environments that do not allow the use of big workstations. Sketches drawn by hand, however, are at risk of becoming smudged or damaged and have to be entered into the CAD platform manually. With RONIDraftboard it is possible to sketch tube systems on a tablet-PC, a lightweight touchscreen computer that can be used on-site, to create digital drawings. Lengths can be entered, elements can be placed, and worksheets can be created. For further processing the drawing can be exported to RONIIsoBuilder or RONIKolli7. 3R software solutions – Germany

THE capabilities of machines for tube processing have developed significantly in recent years, especially due to innovations in design concepts and control software. At international trade shows machine manufacturers present solutions to problems that were deemed impossible as little as ten, even five years ago. But even the most innovative and capable machine is dependent on accurate data in order to attain its full potential. The software applications by 3R software solutions are designed to assist the user at every part of this process, either as stand-alone programs that augment existing IT-structure, or as integrated software framework. One of the first tasks when designing a pipeline system is to draw up the schematics, to see where it fits into the overall project. RONIR2D is one of the programs used for this purpose. It automatically classifies all used components, including their material and nominal diameters, and creates a symbol key based on the included elements. It also automatically generates bills of material for purchasing and the construction department, and assigns a logical and unique number to each component of the diagram. The application uses a database to store element information, and thus it is possible to calculate eg the weight of a particular tube, or the centre of gravity of the entire system. The system can also be tested for logical consistency, and automatically blocks the user from accidentally using incompatible materials. Using the integrated export function it is possible to save the P&I diagram in different formats, so it can be used in the next step in the process. The construction department has the task of turning the two-dimensional P&I diagrams into three-dimensional pipeline systems. This is usually done by splitting the entire system into segments, and creating isometric drawings (isos) for each of them. These drawings can then be subdivided into smaller sections (spools), which can be manufactured in the workshop and assembled on-site. RONIIsoBuilder is designed to not only create these isos, but also to import them from a variety of third-party platforms. Since RONIIsoBuilder focuses on pipeline elements and fittings it offers a large range of features specifically designed for the tube industry. One major advantage of RONIIsoBuilder is that all fabrication-relevant data can be extracted from the iso, and do not have to be calculated manually. Besides worksheets

and part lists for every drawing itself, it is possible to create individual worksheets and lists for every spool composing the drawing. The actual cutting length can be determined, and CNC-data for the various machines in the workshop, such as the bending machine or the flame-cutting machine can be calculated. In order to determine if a spool can be fabricated with the existing machines and tools, a bending simulation program like RONIKolli7 is indispensable. By creating virtual models of the machine and all associated tools, it is possible to test a tube for collision with the machine, the tool, or the environment. In case of interference the software can automatically look for alternatives within the capabilities of the machine and following customisable parameters. The more complex the machine, the more options the program has: simple three-axis benders for example may allow a reversal of the rotation direction or the bending order, as well as a correction feed. Besides a mere simulation of the bending process RONIKolli7 offers features for flange bending and the calculation of flange displacement, cycle time approximation, functions for the creation of tube coils and segment bends, and the consideration of material traits, to account for springback and traction reductions. A newly developed optional feature enables the user to create models of customised tools for very complicated bends. The CNC-data required to fabricate the tube can be printed out on worksheets or in many cases exported directly to the bending machine. Often all that is required of the machine operator is to load the tube into the machine, confirm the data on his screen, and supervise the bending process. Once the entire system has been divided into sections and spools, these spools have to be manufactured. Here it is important to both minimise the need for manual calculations and to arrange the order of the spools for fabrication to reduce changeover times at the various machines. The 3R RAMP system consists of a core application and various modules, each of which controls one of the aspects of fabrication. Data generated from isometric drawings in RONIIsoBuilder is bundled and can be arranged into fabrication packets, always considering machine utilisation and available material. Cutting lists are optimised, so the amount of scrap is reduced as much as possible. Bending lists are created in

Fax: +49 2381 9724 711 Email: c.tripscha@3-r.de Website: www.3-r.de

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N ovember 2010

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