BACKGROUND

[00001] The following includes information that may be useful in understanding the present disclosure. It is not an admission that any of the information provided herein is prior art nor material to the presently described or claimed inventions, nor that any publication or document that is specifically or implicitly referenced is prior art.

[00002] Many industrial manufacturing processes use large storage tanks for housing and blending liquids. Liquid viscosity can be controlled by applying heat to facilitate blending, pumping and conveying the liquids. The liquid must remain heated while it is stored or blended inside of the tank. Typically, the liquid is heated by passing a heated medium, such as steam, through a coiled pipe heat exchanger allowing the liquid inside the tank to be heated and thinned. Until now, pipe coils have been installed inside of these tanks by offsite pre-fabrication in one form or another.

[00003] The traditional methods of tank coil building require the pipes to be bent in sections with each bent section welded together to form the coils. This is all done outside of the tank. Once the entire length of the coil is built, the assembly must be inserted into the tank. Insertion into the tank can be done at the tank manufacturing facility or onsite where the tank will be installed, depending on the size of the tank. Then, the coil assembly must be lifted into place with a crane. The coils must also be transported to the job site for tank assembly, another expensive and logistical endeavor.

[00004] Another issue that arises is the need for rebuilding or replacing aged tank coils. The current method for replacing these coils requires rebuilding them one piece at a time. Rebuilding them one piece at a time is labor-intensive and requires many hours to complete with much of the welding and fabrication work carried out inside the tank.

[00005] What is needed is a product that will allow in situ construction and on-site installation of a helical tank coil.

SUMMARY

[00006] In view of the foregoing disadvantages inherent in the known construction art, the present disclosure provides a novel pipe bender. The general purpose of the present disclosure, which will be described subsequently in greater detail, is to provide a pipe bender usable within an industrial tank. [00007] A portable pipe bending apparatus or machine comprises a main body with two primary components, a top plate, and in some embodiments a bottom plate. A pressing assembly and a stationary assembly are part of the main body of the machine. The pressing assembly is disposed inside of the stationary assembly and both the pressing assembly and the stationary assembly form a platform for dies suitable for bending pipe.

[00008] At least one of the dies is connected by a shaft and bearing block to a motor, such as a hydraulic motor. The dies are sized to engage a pipe that is to be bent. The pressing assembly rides in a slot in the top plate, the bottom plate, or both and is actuated by a hydraulic piston disposed between the pressing assembly and the back of the stationary assembly. Each piece of the machine is designed to be handled by one person and to fit through an access port in an industrial tank.

[00009] In some embodiments, the pressing assembly and stationary assembly are constructed out of a lamination of metal plates stacked and pinned together to make the pressing assembly and the stationary assembly. In some cases, each plate weighs less than 70 pounds. In some embodiments, the die mounted on the pressing assembly is movable front to back on the machine, and two dies mounted on the stationary assembly are fixed. When the piston is activated, the pressing assembly moves toward the die end of the machine capturing the pipe between the three dies. The movable or sliding die lies between the stationary dies and off of an axis between the stationary dies.

[00010] In some embodiments, the laminated plates can have more than one shape and more than one weight.

[00011] A method of using the pipe bending machine includes delivering the components of the machine through an access port, assembling the components into the machine, supplying pipe through the access port to the machine, making the pipe coil, disassembling the machine, passing the components of the machine out of the tank through the access port, and loading components on to a truck or other transportation method.

[00012] For purposes of summarizing the invention, certain aspects, advantages, and novel features of the invention have been described herein. It is to be understood that not necessarily all such advantages may be achieved by any one particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein. The features of the invention which are believed to be novel are particularly pointed out and distinctly claimed in the concluding portion of the specification. These and other features, aspects, and advantages of the present invention will become better understood concerning the following drawings and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The figures which accompany the written portion of this specification illustrate embodiments and methods of use for the present disclosure, a portable modular pipe bending machine and method, constructed and operative according to the teachings of the present disclosure.

FIG. 1 is a perspective view of the inventive pipe bender.

FIG. 2A is an alternative perspective view of an inventive pipe bender.

FIG. 2B is an exploded perspective view of the pipe bender of figure 2A.

FIG. 2C is an exploded perspective view of the present assembly contained inside the pipe bender of FIG. 2A.

FIG. 3A is a top schematic view of an inventive pipe bender.

FIG. 3B is a top schematic view of the pipe bender of FIG. 3A with some of the top pieces removed. FIG. 4 is a perspective representation of an industrial tank with an assembled pipe bending machine inside the tank.

FIG. 5 is a perspective view of a plate component of an inventive pipe bender.

FIG. 6 is a perspective view of another plate component of an inventive pipe bender.

FIG. 7 is a perspective view of another plate component of an inventive pipe bender.

FIG. 8 is a perspective view of another plate component of an inventive pipe bender.

FIG. 9 is a flow chart representing a method of using an inventive pipe bender.

The various embodiments of the present invention will be described in conjunction with the appended drawings, wherein like designations denote like elements.

DETAILED DESCRIPTION

[00013] This machine allows the pipe coil installation on-site in an existing industrial tank. It also allows existing coils needing refurbishment or rebuilds to be quickly repaired less expensively than current methods. The modular coil bending machine is a system that can be used by tank building manufacturers, Industrial fabrication, and pipe fitting contractors. When using this modular system, the contractor installs and mounts the bending machine inside the tank. As the pipe coils are bent, they rest on a support system as they work their way up the inside walls. The support system can be fabricated as a structure in the tank with steel channel and round stock, or other suitable material. In some embodiments, the machine has ¾" steel plates that are sized and designed to be passed through a tank opening that is 18" diameter or smaller.

[00014] The contractor builds the pipe coils inside the tank by feeding the welded pipe sections continuously through the tank opening. This allows coil construction even when access is limited. This machine eliminates many issues including transportation and logistics issues, labor and material costs, and crane expenses.

[00015] FIG. 1 illustrates a simplified version of the portable pipe bender 100 according to an embodiment of the invention. Pipe bender 100 comprises main body 101 and stand 30. Main body 101 comprises pressing assembly 120 and stationary assembly 140. Stationary assembly 140 forms a rigid structure that surrounds pressing assembly 120. Pressing assembly 120 rides inside the opening in stationary assembly 140 on tracks (not shown) in or on stationary assembly 140. Pressing assembly 120 is powered by attached hydraulic piston assembly 130 (hydraulic piston). Hydraulic piston 130 also attaches to stationary assembly 140, such that as hydraulic piston 130 expands, pressing assembly 120 moves toward a die end of main body 101.

[00016] Stationary assembly 140 is made up of several laminated plates 150 such as rear support laminated plate 152 (RS laminated plate) (best seen in FIG. 5), Stationary die support laminated plate 156 (SDS laminated plate) (best seen in FIG. 6), top plate 153, and bottom plate 154 (best seen in FIG. 7). In some embodiments, top plate 153 and bottom plate 154 are substantially the same. Laminated plates 150 stack together to form main body 101. Once assembled, fasteners 110 connect laminated plates 150 together. Depending on the embodiment, fasteners 110 are selected from any one or any combination of bolts, pins, dowels, etc., and are held by bolt action or friction, etc.

[00017] Some embodiments have different types of laminated plates 150: top and bottom plates 153, 154; SDS laminated plate 156; PA laminated plate 121, and RS laminated plate 152. Laminated plates 150 are fastened together using pins or bolts 110 that are perpendicular to laminated plates 150. Stationary assembly 140 comprises top and bottom plates 153, 154; SDS laminated plate 156, and RS laminated plate 152. The pressing assembly 120 comprises PA laminated plate 121.

[00018] Stationary assembly 140, in this embodiment, is made up of two hydraulic motors 190, two bearing blocks 172, and two stationary dies 170 mounted on the structure formed by laminated plates 150.

[00019] In these or other embodiments, stationary assembly 140 comprises a stack of RS laminated plates 152, SDS laminated plates 156, top plate 153, and bottom plate 154. SDS laminated plate 156 is shaped like a "u" with squared edges (see FIG. 6), and RS laminated plate 152 is rectangular (see FIG. 5). Top plate 153 and bottom plate 154 are substantially rectangular but larger than RS laminated plate 152. In some embodiments, top plate 153 has top-plate cut out 142. A stack of RS laminated plates 152 space one end of stationary assembly 140 apart. RS laminated plates 152 are located opposite of the bearing and pipe bender 100. A stack of SDS laminated plates 156 space the other end of stationary assembly 140 apart. A stack of SDS laminated plates 156 also serves to mount various components of the pipe bender 100 (and are discussed more fully below). Top plate 153 and bottom plate 154 connect to the top and bottom of the stack of RS laminated plates 152 and the stack of SDS laminated plates 156. Hydraulic piston 130 sits inside the assembly of laminated plates 150. In some embodiments, the component of pipe bender 100 that comprises a stack of RS laminated plates 152 can be substituted for a solid piece.

[00020] Jumping to FIG. 2B, the stack of SDS laminated plates 156 mounts at least one stationary die 170. Depending upon the embodiment, stationary die 170 is powered or not powered. Stationary die 170 connects to the stack of SDS laminated plates 156 through bearing block 172. Die retainer 174 retains stationary die 170 to a shaft (not shown). Two stationary dies 170 are situated substantially parallel to top plate 153. Top plate 153 is the upper portion of the stationary assembly 140. Hydraulic switch 192 is attached to top plate 153, in some embodiments.

[00021] Pressing assembly 120 comprises a stack of pressing assembly laminated plates 121 (PA laminated plate) (best seen in figure 8). Sliding die 180 mounts to pressing assembly 120 through bearing block 172 and die retainer 174, as described above. Stationary die 170 and sliding die 180 can have a variety of thicknesses and diameters chosen to suit the size of the pipe to be coiled. Either type of die can be powered by a motor or not, provided that at least one die is powered. In some embodiments, 1, 2, or 3 dies are powered by motors. Once assembled, stationary dies 170 form one side of the triangle with sliding die 180 forming the opposite point, in some embodiments.

[00022] Any type of motor recognized by those of ordinary skill in the art as suitable in pipe bending equipment can be used in various embodiments of the current invention, provided that the motor can pass through port 25 (shown in figure 4). Some embodiments employ electric motors; some embodiments employ hydraulic motors; some embodiments employ a mix of electric, hydraulic, or other motors. In some embodiments, the hydraulic or electric motors run synchronously.

[00023] Continuing with figure 1, pressing assembly 120 moves along inner slot 143 or a track in or on SDS laminated plate 156. Pressing assembly 120 attaches to hydraulic piston 130. Activation of piston 130 moves sliding die 180 closer to or further from stationary dies 170. Some embodiments use an actuator other than a hydraulic piston in place of hydraulic piston 130. Moving sliding die 180 towards stationary dies 170 increases sideward pressure on pipe 10 from both sliding die 180 and stationary dies 170. The movement tends to squeeze pipe 10 between dies 170 and die 180. The pressure generated between pipe 10 and dies 170, 180 increases frictional forces between the pipe and the dies. This allows dies 170, 180 better ability to translate pipe 10 between dies 170, 180, a necessary movement to roll or bend pipe 10 into a coil. For embodiments that use hydraulic motors 190, pipe bender 100 also comprises a hydraulic power unit and electro-mechanical control and valving to distribute the hydraulic fluid appropriately to turn the motors. In some embodiments, electro-mechanical control and valving distribute hydraulic fluid to operate one or more motors 190 in the chosen direction. In some embodiments, electro-mechanical control and valving distribute hydraulic fluid to operate hydraulic piston 130 in one or both directions, as well. Electro-mechanical control and valving function components could be implemented in different ways. Electro-mechanical control and valving is represented in the figure by hydraulic switch 192, but such a system would use other components as recognized by those of ordinary skill in the art and including at least hydraulic hoses. For embodiments that use electric activators, electrical power and switching are used, and this is within the level of skill of those of ordinary skill in the art, as well.

[00024] Pipe bender 100 has dies and motors sized to operate on standard nominal pipe I.D. sizes from 1/2" to 3". Pipe bender 100 can also operate on nominal pipe and tubing wall thickness from schedule 10 to schedule 80. In some embodiments, pipe 10 comprises a material that comprises any one or any combination of stainless steel, galvanized steel, black steel, copper, aluminum, brass, or bronze.

[00025] FIG. 2A shows an alternative view of pipe bender 100. FIG. 2B is an exploded view of FIG. 2A. In FIG. 2B, top plate 153, bottom plate 154, RS laminated plate 152, and TDS laminated plate 156 can be seen. FIG. 2B illustrates how laminated plates stack together. FIG. 2C is an exploded view of pressing assembly 120.

[00026] FIG. 3A depicts an upper view of pipe bender 100; as described above, top plate 153 serves as a mount for hydraulic switch 192 and forms the top layer of the plate laminations that form stationary assembly 140. Figure 3B depicts a similar view to that of FIG. 3A, but top plate 153 has been removed to reveal the interior of pipe bender 100.

[00027] Figure 4 depicts a portion of tank 20 having port 25. Pipe bender 100 is shown assembled inside tank 20. Neither tank 20 nor pipe bender 100 are necessarily drawn to scale in this figure. Nonetheless, those of ordinary skill in the art will recognize that all components of pipe bender 100 should fit through port 25. In some embodiments, all components of pipe bender 100 must fit through port 25.

[00028] FIG. 5 depicts RS laminated plate 152 having holes 111 for receiving fastener 110 (shown in figure 1) to form a stack of RS laminated plates 152. In the assembly, fasteners 110 hold together the stack of RS laminated plates 152 arranged between top plate 153 and bottom plate 154-starting with top plate 153, followed by the stack of rear support plates 152, and ending with bottom plate 154.

[00029] FIG. 6 depicts SDS laminated plate 156, a part of stationary assembly 140, having cut out 141, holes 111 for fasteners 110, and shaft holes 112 that pass the shafts (not shown) of hydraulic motor 190 and that support stationary die 170. Some of holes 111 mount bearing block 172 to stationary assembly 140. FIG. 7 depicts top plate 153 (which in some embodiments has substantially the same shape as bottom plate 154). Top plate 153 has cut out 142 that allows inspection of pressing assembly 120. Mounting-pin hole 113 receives a pin (not shown) that connects hydraulic piston 130 to stationary assembly 140.

[00030] FIG. 8 depicts PA laminated plate 121. In some embodiments, PA laminated plate 121 is T-shaped and comprises mounting-pin hole II hole 114 for receiving a pin (not shown). The pin connects hydraulic piston 130 to PA laminated plates 121. PA laminated plate 121 comprises holes 111 that hold the plates together and mount bearing block 172, which ultimately mounts sliding die 180 appropriately for pressing assembly 120 to function.

[00031] In some embodiments, the modular system has laminated steel plates 150 that are bolted together to form the body and structure. There are eight, ¾" thick, mild steel plates 150 that make up the pipe bender 100. These plates weigh approximately 50 lbs each, which allows them to be maneuvered in and out of the tank access port 25. In these or other embodiments, the plates can be manually maneuvered. Plates 150 are sized and designed to pass through port 25, which in some cases is 18 inches or smaller in diameter. In some embodiments, all components of pipe bender 100 fit through port 25 having a diameter of less than 21, 20, 19, 18, 17, or 16 inches. In some embodiments, all components of pipe bender 100 except for the hydraulic power unit fit through port 25 having a diameter of less than 21, 20, 19, 18, 17, or 16 inches. There are two additional plates, top and bottom, forming hydraulic cylinder support 152. The eight plates are arranged to function as the support structure (main body 101) of bending machine 100. The plates stack together to form main body 101. Main body 101 is made with the plates, so that it can be assembled or disassembled quickly in areas of limited access. In various embodiments, the number, thickness, and composition of laminated steel plates 150 varies. For instance, plates 150 could comprise aluminum, some other form of steel, or any other material known to be useful by those of ordinary skill in the art; there could be fewer than or more than eight plates 150, or the plates could be thicker or thinner than three quarters of an inch depending upon which of the embodiments of the invention was constructed. All of these variables can be chosen by those of ordinary skill in the art.

[00032] The plates 150 are stacked to make up main body 101, which provides a structure for attachment of drive motors 190 and bending dies 170,180. Additional structure plates are added to support the hydraulic ram cylinder 130, which moves to apply pressure to pipe 10 as it passes through bender 100. This wil l cause pipe 10 to start forming a curve which can be adjusted to form a coil, which will work its way up toward the top of the tank.

[00033] The rolling bender method works by having three bending dies 170, 180 that are shaped to fit around the outside diameter of pipe 10 with two stationary dies 170 on one side and an adjustable sliding die 180 on the opposite side, centered between them. In some embodiments, each wheel die has a dedicated hydraulic motor 190 attached that turns the dies in synchronous motion, pulling the pipe through. [00034] In use, pipe bender 100 is delivered to a tank at a jobsite, tank 20, which is to receive a pipe coil. Pipe bender 100 can be delivered to the jobsite either assembled or disassembled.

[00035] Figure 4 depicts pipe bender 100 showing through access port 25 of tank 20. Pipe bender 100 is assembled inside tank 20 to prepare it to process pipe 10. As those of ordinary skill in the art will recognize, in this embodiment, every component of pipe bender 100 is small enough to pass through port 25. In these or other embodiments, every component of pipe bender 100 weighs little enough to be transported by 1 or 2 workers. In some embodiments, the heaviest component weighs less than 100, 80, 70, 60, 50, 40, 30, 20, or 10 pounds.

[00036] If assembled, pipe bender 100 is disassembled, and in some embodiments, each piece is manually passed through port 25. Once inside tank 20, pipe bender 100 is reassembled.

[00037] In some embodiments, portable pipe coiler 100 is assembled as follows:

1. The machine parts are passed through port 25 at the bottom of tank 20.

2. A support structure for the coil pipe is built inside tank 20. In some embodiments, this uses channel pieces. In these or other embodiments, these channel pieces are welded vertically inside tank 20 and equally spaced around tank 20. These support the pipe coil.

3. The machine parts are assembled by starting with an anchor plate (not shown) that can be attached to the support structure.

4. The anchor plate and bottom plate 154 are then supported by two leg stand supports, such as those of stand 30.

5. The remaining plates are stacked in consecutive order to form main body 101.

6. Bearing blocks, shafts, motors 190, and other operating components are added, and then the whole unit is bolted together.

7. A hydraulic pump is set-up outside tank 20 remote from the machine. Hydraulic hoses are run through port 25 to motors 190. In some embodiments, motors 190 are electric, and power cables are run through port 25 to motors 190. In some embodiments, the hydraulic pump is inside tank 20. 8. A pendant controller 103 allows bender operation from wherever the operator chooses to observe. In some embodiments, pendant controller 103 is handheld, remote, wireless remote, or any combination of these.

[00038] Once assembled inside tank 20, pipe 10 is fed through port 25 to pipe bender 100 between stationary dies 170 and sliding die 180. Then pendant controller 103 actuates hydraulic piston 130. Operating hydraulic piston 130 can cause hydraulic piston 130 to lengthen and move the pressing assembly 120 toward stationary assembly 140. The movement causes sliding die 180 and stationary dies 170 to press sideways against pipe 10, causing pipe 10 to begin to bend.

[00039] Once the first pipe has started, the second pipe is butt welded from outside the tank. Each pipe is welded to the end of the coil as the coil works its way up the tank. In some embodiments, second pipe 10 is butt welded inside the tank.

[00040] After coiling, pipe bender 100 is disassembled and manually removed through port 25, leaving the pipe coil inside tank 20.

[00041] The embodiments of the invention described herein are exemplary, and numerous modifications, variations, and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the invention. Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers, and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application.

[00042] The steps described in the method of use can be carried out in many different orders according to user preference. The use of "step of" should not be interpreted as "step for", in the claims herein and is not intended to invoke the provisions of 35 U.S.C. § 112(f). It should also be noted that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other methods for pipe in a confined area [NOTE: e.g., different step orders within the above-mentioned list, elimination or addition of certain steps, including or excluding certain maintenance steps, etc.], are taught herein.