1. Field of the Invention

[0001] The present invention relates to coiling of plastic pipe into large pipe coils. In particular to pipe coils that may be up to 5 metres in outside diameter or further, may be up to 3 metres wide or further and a weight may be up to

approximately 8.5 tonnes or more. More particularly to producing pipe coils to the full width, height and weight that may be carried by rail or road freight in a country.

[0002] The present invention more particularly relates to the coiling of polyethylene pipe either singularly or paired with a pipe outside diameter that may be up to approximately 350 mm or further.

2. Description of the Art

[0003] There are various known processes and apparatuses for coiling of plastic pipe into coils. For example CA2,800,713 "Method and apparatus for winding up tubes in spool form and for wrapping the spool formed", US8,944,359 "Machine or winding pairs of tubes parallel to an advancing direction and independent of each other " and US9, 114,896 "Coiling pipes in spool form and tying said spool".

[0004] Coiling plastic pipe into large pipe coils of many tonnes and some metres in width and diameter than that possible with the prior art processes and apparatuses may require sufficient support to the coil winding reel of the coiler machine as well as safe and efficient access and unloading from the coiler of the completed pipe coil. In addition larger pipe coils may need to be unloaded and transported preferably without an expensive and heavy supporting reel or drum within the completed pipe coil. Large pipe coils without internal support during coiler unloading and transport need to have the integrity of the pipe coil windings maintained in order that efficient and safe unwinding of the large pipe coil may occur at the pipe installation site. Furthermore the pipe walls within the pipe coil need to be undamaged and not unduly distorted so that the uncoiled pipe at the installation site performs to specification and / or rating.

[0005] Coiling of large pipe diameters into large pipe coils typically occurs over many hours to up to a day. Accordingly it is also desirable to minimise idle time of a coiler machine during unloading or ejection of a completed pipe coil. Particularly for larger pipe coils where handling is important.

[0006] None of these prior art methods, apparatus or devices provides an entirely satisfactory solution to the provision of pipe coiling to produce large coils to the limit of road or rail transport, nor to the ease of coiling, stability and integrity of the pipe coil, speed of coiling, economical coiling of pipe and safety for large pipe coil handling without or minimal human / manual involvement.

[0007] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application.

SUMMARY OF THE INVENTION

[0008] The present invention aims to provide an alternative pipe coiling arrangement/s, method/s and/or apparatuses which overcomes or ameliorates the disadvantages of the prior art, or at least provides a useful choice.

[0009] In one form the invention provides an apparatus for unloading a large pipe coil from a coiler comprising: a rotatable reel about which a pipe is coiled to form the large pipe coil and the rotatable reel axis of rotation is supported at each opposing end of the reel; a reel outer cylindrical surface formed of multiple, longitudinal and circumferentially spaced apart bars; a first spider and a second spider at opposing ends of the rotatable reel, each spider having a plurality of arms, each opposing arm of the first and second spiders supporting respective opposing ends of a bar of the rotatable reel; the first and second spiders at least one of constrain and support the coiling pipe about the rotatable reel; and the first spider also includes the axis of rotation support at a corresponding end of the rotatable reel; wherein the first spider is separable from the plurality of bars of the reel and the first spider supports the pipe coil as the first spider separates from the bars of the reel; whereby the pipe coil is unloaded from the coiler.

[0010] The second spider arm supports to the bars of the reel are moveable such that the diameter of the reel is adjustable.

[0011] The apparatus further including a lifting table for supporting a lower portion of the pipe coil as the first spider separates from the reel.

[0012] The lifting table includes a flap which conforms to a lower portion of the pipe coil.

[0013] The lifting table includes one or more projections to constrain the pipe coil tail.

[0014] The first spider includes a moveable support prong to each arm of the spider, wherein the support prongs support the pipe coil as the first spider separates from reel.

[0015] The apparatus further including a convex spreader beam to support an upper portion of the pipe coil.

[0016] The convex spreader beam has a width is less than a distance between the arms of the first spider.

[0017] The convex spreader beam has a width which extends towards a distance between the arms of the first spider.

[0018] The apparatus wherein a convex upper surface of the convex spreader beam has a radius of curvature substantially corresponding to a radius of curvature of at least one of the pipe coil and the reel.

[0019] The apparatus further including: one retractable strapping channel between the first and second spiders, wherein the retractable strapping channel extends radially into the reel to complete a strapping channel circuit for strapping of the pipe coil upon the reel when the first spider has separated from the reel.

[0020] The longitudinal, coiling axis of rotation of the reel is horizontal.

[0021] In another form, the invention provides a method for unloading a pipe coil from a pipe coiler, the steps including: supporting a lower portion of the pipe coil with a lifting table, separating a first spider from a reel to which the pipe coil was coiled, and removing the pipe coil from between the separated space between the first spider and an open end of the reel whereby the pipe coil is unloaded from the coiler. [0022] The method further including the step of: conforming the lifting table to the lower portion of the pipe coil.

[0023] The method further including, prior to separating the first spider from the reel, the steps of: supporting the pipe coil with a plurality of support prongs from the first spider arms, and retracting inwardly a plurality of circumferential bars of the reel to release the pipe coil.

[0024] The method further including, after separating the first spider from the reel, the step of: inserting a convex spreader beam between the first spider arms and below an uppermost portion of the pipe coil.

[0025] The method further including after inserting the convex spreader beam, the steps of: retracting the support prongs away from the pipe coil, and lifting the pipe coil away from the space between the first spider and an open end of the reel by using the convex spreader beam.

[0026] In an alternate form, the invention provides a pipe clamp comprising: two clamping jaws, an inner surface of each clamping jaw is recessed to be substantially conformal with a pipe start end received by the pipe clamp, and at least one clamping jaw has at least one of an aperture and a recess adapted to receive a drilling pin, wherein the drilling pin is drilled through the pipe start end clamped within the two clamping jaws and the drilling pin remains within the pipe clamp and the pipe start end to aid in securing the pipe start end to the pipe clamp.

[0027] The drilling pin longitudinal axis is substantially parallel to a longitudinal axis of a reel of a coiling machine.

[0028] The pipe clamp wherein a substantially conformal inner surface of each clamping jaw is adapted to at least one of: minimise a distortion to the pipe start end, securely clamp the pipe start end and release the pipe start end.

[0029] The substantially conformal inner surface of each clamping jaw is further adapted to present opposing side walls of the pipe start end such that the drilling pin does not bind during drilling, securing and release of the pipe start end.

[0030] The inner surface of each clamping jaw is further conformally recessed so as to include a second pipe start end within the pipe clamp.

[0031] In yet another form, the invention provides a coiler for coiling large diameter plastic pipe comprising: a rotatable reel about which a pipe is coiled to form a large pipe coil and the rotatable reel axis of rotation is supported at each opposing end of the reel; a first spider and a second spider at opposing ends of the rotatable reel, the first and second spiders to at least one of constrain and support the coiling pipe about the rotatable reel; and a pipe clamp is attached to the rotatable reel; wherein a pipe start end of the pipe for coiling is secured to the reel in order to coil a pipe.

[0032] The pipe clamp is located outside of the portion of the reel used for coiling pipe.

[0033] In a further form, the invention provides a coiler for coiling large diameter plastic pipe comprising: a rotatable reel about which a pipe is coiled to form a large pipe coil and the rotatable reel axis of rotation is supported at each opposing ends of the reel; a first spider and a second spider at opposing end of the rotatable reel, the first and second spiders to at least one of constrain and support the coiling pipe about the rotatable reel; a pipe haul-off to control a feed of the pipe to the rotatable reel, the pipe haul-off being located to a front of the reel; and an indexing pin located at substantially an opposing side of the reel to the pipe haul-off; wherein the indexing pin pushes the pipe being coiled against adjacent pipe coils about the reel.

[0034] The indexing pin is attached to a paddle and the paddle compresses the coiling pipe to the reel.

[0035] In another form, the invention provides a coiler for coiling large diameter plastic pipe comprising: a rotatable reel about which a pipe is coiled to form a large pipe coil and the rotatable reel axis of rotation is supported at each opposing ends of the reel; a first spider and a second spider at opposing end of the rotatable reel, the first and second spiders to at least one of constrain and support the coiling pipe about the rotatable reel; a pipe haul-off to control a feed of the pipe to the rotatable reel, the pipe haul-off being located to a front of the reel; and a paddle located substantially at an opposing side of the reel to the pipe haul-off; wherein the paddle compresses the coiling pipe to the reel.

[0036] The coiler further including a second paddle also located

circumferentially about the reel.

[0037] In an alternate form, the invention provides a coiler for coiling large diameter plastic pipe comprising: a rotatable reel about which a pipe is coiled to form a large pipe coil and the rotatable reel axis of rotation is supported at each opposing ends of the reel; a first spider and a second spider at opposing end of the rotatable reel, the first and second spiders to at least one of constrain and support the coiling pipe about the rotatable reel; and at least one retractable strapping channel between the first and second spiders; wherein the retractable strapping channel extends radially into the reel to complete a strapping channel circuit for strapping of the pipe coil upon the reel when the first spider has separated from the reel.

[0038] In yet another alternate form, the invention provides a method for strapping of a completed pipe coil, the steps including: extending inwardly at least one strapping channel into the reel, completing a strapping circuit about a completed coil upon the reel, strapping the completed coil, retracting radially at least one strapping channel from the reel and the completed coil, and continuing pipe coiling to the reel.

[0039] In another form, the invention provides a coiler for coiling large diameter plastic pipe comprising: a rotatable reel about which a pipe is coiled to form a large pipe coil and the rotatable reel axis of rotation is supported at each opposing ends of the reel; a first spider and a second spider at opposing end of the rotatable reel, the first and second spiders to at least one of constrain and support the coiling pipe about the rotatable reel; and the first and second spiders each have a plurality of arms, each opposing arm of the first and second spiders supporting opposing ends of a bar of the rotatable reel; wherein the spider arm supports to the bars of the reel are moveable such that the diameter of the reel is adjustable during coiling to secure the partially completed pipe coil upon the reel.

[0040] Further forms of the invention are as follows: a method of coiling pipe as described herein and with respect to figures 1 to 24; a pipe coiling apparatus as described herein and with respect to figures 1 to 24; a method of unloading a pipe coil from a pipe coiler as described herein and with respect to figures 13 to 21; and an unloading apparatus or system for pipe coils from a pipe coiler as described herein and with respect to figures 13 to 21.

[0041] Further forms of the invention are as set out in the appended claims and as apparent from the description. DISCLOSURE OF THE INVENTION

BRIEF DESCRIPTION OF THE DRAWINGS

[0042] The description is made with reference to the accompanying drawings, of which:

[0043] FIGURE 1 is a schematic diagram of a perspective view of a coiling apparatus machine or coiler.

[0044] FIGURE 2 is an alternate perspective view of FIGURE 1 that also views to the front of the coiler but from the side of second spider.

[0045] FIGURE 3 is an alternate perspective view of FIGURES 1 and 2.

[0046] FIGURE 4 is a schematic photograph / drawing of a perspective view of the rail on each of the first spider arms as shown in FIGURE 2.

[0047] FIGURES 5 and 6 are schematic photographs / drawings of perspective views of a saddle coupler described above with respect to FIGURES 2 and 4.

[0048] FIGURE 7 is a schematic drawing / photograph in perspective view to a new pipe latch device or conformal pipe clamp shown in FIGURE 1.

[0049] FIGURE 8 is to a paired pipe latch/clamp device for clamping the start end of two pipes to be coiled in a paired or double arrangement.

[0050] FIGURE 9 is a schematic diagram of a front perspective view of the rear paddle units shown in FIGURE 3.

[0051] FIGURE 10 is a schematic diagram showing a perspective view of an automatic strapping unit for intermediate strapping of a partially completed the pipe coil and final strapping of a completed pipe coil by the coiler.

[0052] FIGURE 11 is an enlarged view of the rectangular boxed region of FIGURE 10 showing the strapping unit with the strapping channel circuit.

[0053] FIGURE 12 is a perspective view of only the strapping unit with the strapping channel circuit about a cross-section of a partially completed pipe coil.

[0054] FIGURES 13 to 21 are a sequence of schematic drawings in perspective view from the front of the coiler showing the ejection / unloading of the large, completed pipe coil from the reel of the coiler. [0055] FIGURE 22 is a schematic perspective view diagram / photograph showing an overhead crane lifting a completed pipe coil into a cradle or stand.

[0056] FIGURES 23 and 24 are schematic diagrams / photographs in perspective view of examples of the two ski-like guides with mounting brackets detached from the haul-off unit.

DETAILED DESCRIPTION.

[0057] FIGURES 1, 2 and 3 are schematic perspective diagrams showing a large pipe coiling apparatus / machine suitable for coiling plastic pipe into a full width coils. That is, a coiler 110 machine that may produce pipe coils to the full width, height and weight that may be carried by rail or road freight in a country. For example the pipe coils may be up to approximately 5 metres in outside diameter or larger, up to approximately 3 metres wide or wider and a weigh up to approximately 8.5 tonnes or more. More preferably the pipe coil may be up to approximately 4900mm outer diameter and up to approximately 2500 mm wide or up to approximately 2400 mm wide for road freight in Australia as one example. It will be readily appreciated that "over-size" road or rail transport may allow for larger pipe coils to be produced by the invention and transported. Prior art pipe coils are typically only half to a third or a quarter of the coil widths produced by the invention/s

[0058] By way of example: the pipe coils produced by the invention/s may be suitable for road or rail transport by a new and inventive freight transporter as described in the Australian Innovation Patent Application "A Trailer", number AU 2016100252 filed 8 March 2016, the contents of which are incorporated herein by reference. In addition the pipe coils may also be suitable for de-coiling at the installation site or remote site by a new and inventive pipe de-coiler as described in the PCT Patent Application "A De-Coiling Trailer for Plastic Pipe ", application number PCT/AU2017/050184 filed 2 March 2017, the contents of which are incorporated herein by reference.

[0059] In addition the pipe making up the coil may be coiled by the coiler 110 in a single or paired arrangement. The plastic pipe for coiling may have an outside diameter up to approximately 350 mm or preferably up to approximately 315 mm or more preferably approximately between 90 and 280 mm or approximately between 110 to 250 mm, depending on the pipe plastic material and pipe wall thickness. In one example the plastic may be a polyethylene.

[0060] FIGURE 1 is a schematic diagram of a perspective view of the coiling apparatus machine or coiler 110. The front of the coiler 110 is shown, which typically faces the pipe extrusion line producing the pipe for immediate coiling. FIGURE 1 also shows the coiler 110 in an open configuration or open state to allow for the removal of a completed pipe coil. The coiler has a reel 112 with a central drum 114 made up of six bars (for example) or shells 116, each of the bars of the reel are supported at respective ends by a first spider 118 and a second spider 120. The first and second spiders each have corresponding arms 121 attaching to the bars 116 of the drum 114. Thus coiler reel 112 used to coil a pipe upon is made up of the central drum 114 of multiple circumferentially and longitudinally arranged bars 116 with the first and second spiders 118, 120 at opposing ends of the drum 114. The open configuration of the coiler 110 is where the first spider 118 is separated or disengaged from the drum 114. A closed configuration of the coiler 110 is shown in FIGURE 21, ready for coiling of pipe. A completed large pipe coil 2212 upon the coiler 110 is shown in FIGURE 22.

[0061] The first spider 118 is mounted on and rotates upon an end support 124. The end support 124 is mounted on a rail bed 126 so that the end support 124 and first spider 118 may be moved to and from the rest of the reel 112 assembly of the bars 116 and the second spider 120. The second spider 120 is mounted and rotates upon another, opposing end support 128. The opposing end support 128 is fixed in position with the footings 130 of the coiler 110. The coiler 110 for large pipe coils 2212 especially features a suitably large reel 112 with a longitudinal axis of rotation through the reel 112 which is rotatably supported at both ends of the reel 112 in order to cope with the large pipe coiling forces and weight of the pipe coil. In addition and advantageously to unload or eject the pipe coil 2212, 1312 the first spider 118 is separable and allows for pipe coiling to resume whilst further unloading of the pipe coil 1312, 2212, as described further below with respect to FIGURES 13 to 21.

[0062] The second spider 120 on each arm 121 may have a mobile flange or spider arm support 132 that supports each bar 116 of the drum 114. The spider arm supports 132 or flanges may be moveable and remotely driven along each arm 121 of the second spider 120 so that the position of each bar 116 and thus the diameter of the drum 114 for pipe coiling may be varied. Further details to the adjustable drum diameter and the first spider 118 are described below with respect to FIGURES 2, 4 to 6.

[0063] The first spider 118 on each arm 121 has support prongs 134 that may be moved and remotely driven along the arms 121 of the first spider 118. The support prongs may be used during the unloading of a pipe coil 1312, 2212 from drum 114. The support prongs are described further with respect to FIGURES 13 to 21.

[0064] Also shown in FIGURE 1 are ejectors 136 that may traverse along each bar 116 from the second spider 120 to the first spider 118 in order to aid in ejecting a completed pipe coil from the drum 114 of the coiler 110. The ejector 136 for each bar 116 may be driven and operated remotely as well as automatically. The operation of the ejectors 136 is described further below with respect to FIGURES 13 to 21. The ejectors may also be termed flange or side supports for the spider arms.

[0065] In FIGURE 1 adjacent and parallel with each bar 116 are internal strapping channels 138 or race-ways for conveying and supporting a strap about the inside of the pipe coil during coiling and after coiling. Strapping or tying of the pipe coil windings is done during coiling and at completion in order to maintain the integrity of the pipe coil. The strapping and the use of a strapping channel circuit or race-way is described further with respect to FIGURES 3, 8, 10 to 12. A completed pipe coil 2212 is shown in FIGURE 2212 with intermediate (applied during coiling) strapping and final strapping about all the pipe coil windings.

[0066] A pipe latch or conformal pipe clamp 140 is shown attached to a bar 116 and adjacent the second spider 120 so as to be outside of the coil winding portion of the drum 114. The conformal pipe clamp is described further at FIGURES 7 and 8.

[0067] Also shown in FIGURE 1 is a lifting table 142 that may be raised and lowered in order to support the completed pipe coil during unloading. The operation of the retractable lifting table is described further below with respect to FIGURES 13 to 21. The lifting table is shown in the lowermost, retracted position typically used during the coiling process. The lifting table 142 may be sloped 144 towards the rear of the lifting table 142 in order to conform with and support the completed pipe coil. In addition two front moveable flaps or leaves 146 of the lifting table are shown raised as may be used to further support the lower portion of the completed pipe coil during the pipe coil ejection / unloading. The front flaps 146 of the lifting table 142are also moveable so that they may be lowered during pipe coiling.

[0068] The lifting table shown in FIGURE 1 may also be split in two so that half coils or less may be produced. In such an operational mode only half of the lifting table is used to support the half or third width pipe coil during ejection / unloading.

[0069] The lifting table may also feature optional, moveable side discs or projections 148 as shown. The side discs may be used to restrain a tail end of the pipe at the end of the coiling process and for final strapping.

[0070] FIGURE 2 is an alternate perspective view of FIGURE 1 that also views to the front of the coiler 110 but from the side of second spider 120. A convex spreader beam 212 or lifting arm / shoe is shown in FIGURE 2 in addition to FIGURE 1. The convex spreader beam 212 is used to lift the completed pipe coil by inserting the spreader beam 212 into the upper portion coil center as described further below with respect to FIGURES 13 to 19. The upper surface 214 of the convex spreader beam is shaped so as to be adapted to support or substantially conform with the upper portion of curved inside surface of the completed pipe coil so that the large pipe coil is well supported and lifted without damage. A transverse, horizontal width of the conventional spreader beam 212 may extend towards the available distance between the arms 121 of the first spider 118 in order to maximise the width of the supporting upper surface 214 of the spreader beam 212 to the pipe coil. This is in contrast to prior art spreader beams which are typically cylindrical poles or similar with comparatively narrow supporting surfaces.

[0071] The spreader beam 212 may also have lifting eyes or loops 216 for a crane to lift the completed pipe coil via the convex spreader beam 212. A lifting gantry 218 may be positioned across the rail bed 126 of the first end support 124 to lift and position the spreader beam as described further below.

[0072] FIGURE 2 also shows a pipe haul-off or pulling device 220 that was omitted from FIGURE 1 to improve clarity. The pipe haul-off 220 typically receives pipe from an extrusion line and feeds the pipe to the coiler 110 at a controlled rate. Typically the haul-off 220 may have at least two caterpillar track loops 222 which securely clamp the incoming pipe from an extrusion line or the like. The caterpillar track loops are typically driven so as to control the pipe feed rate to the coiler and in combination with the reel 112 rotation and reel torque, the tension in the pipe being coiled to the reel may also be controlled. The haul-off 220 traverses across the front of the coiler 110 during pipe coiling so as to appropriately position and tension pipe coil windings about the drum 114.

[0073] The haul-off 220 may also include ski like projections at the pipe entry to the haul-off to aid in pipe handling. These ski like projections or guides are described further below with respect to FIGURES 23 and 24.

[0074] At the rear of the coiler 110 and the reel 112 a retractable strapping channel or race-way 224 is shown. The retractable strapping channel 224 may be extended inwardly into the drum 114 in order to mate with an internal strapping channel 138 and complete the strapping channel circuit as described below with respect to FIGURES 3, 10 to 12. The retractable strapping channel 224 is an advantage to providing intermediate strapping of the pipe coil windings at when the first spider 118 is separated from the drum 114. The retractable strapping channel 224 is able to form an intermediate strap for example on the first layer of the pipe coil or with any strap where bayonets may be used. The retractable strapping channel may also be required to make a final strap about the completed pipe coil when the first spider 118 is retracted from the coiler drum 114 in the ejection position or unloading / open configuration.

[0075] In the alternate view of FIGURE 2 the mating face of the first spider 118 arms 121 with the respective ends of the bars 116 is shown. Each arm 121 may have a rail 226 which provides bearing surfaces for a corresponding saddle coupler (not shown) at the end 228 of the corresponding bar 116. The saddle coupler, the adjustable positioning of the bars 116 with respect to the first spider 118 and the adjustable drum diameter are described below with respect to FIGURES 4 to 6.

[0076] The support prongs 134 may also be joined with the rail 226 such that the rail 226 and the support prongs 134 both move radially inwardly and outwardly with respect to the reel 112 longitudinal axis and along the first spider 118 arms 121.

[0077] FIGURE 3 is an alternate perspective view of FIGURES 1 and 2. FIGURE 3 shows the rear of the coiler 110 without the retractable strapping channel 224 in order to improve clarity. Two rear paddles units 312, 314 are shown to the rear of the coiler 110 and the reel 114. An upper 312 and a lower 314 paddle unit are shown with their respective extension tracks and drives towards the reel 114 as well as their traversing tracks and drives parallel with the reel 114 longitudinal axis. The two rear paddle units 312, 314 are used against the pipe coil windings during coiling. The rear paddles are shown and described further below with respect to FIGURE 9.

[0078] FIGURE 4 is a schematic photograph / drawing of a perspective view of the rail 226 on each of the first spider 118 arms 121 as shown in FIGURE 2. The view is from adjacent the bar 116, looking towards the first spider 118 separated from the drum 114 of the bars 116. The rail 226 has two opposed bearing surfaces on either side of the rail 226. In FIGURE 4 one bearing surface 412 on one side of the rail is shown. The two opposed bearing surfaces may not be parallel, but may be optionally slightly tapered inwardly towards the coupling saddle in order to facilitate engagement and movement along the rail 226 by the saddle coupler of FIGURES 5 and 6.

[0079] FIGURES 5 and 6 are schematic photographs / drawings of perspective views of a saddle coupler 512 described above with respect to FIGURES 2 and 4. The saddle coupler 512 located at corresponding ends of each bar 116 of the reel 112 mates or otherwise engages with a corresponding rail 226 on each arm 121 of the first spider 118. The curved inside surfaces 514 of the saddle coupler 512 bear against and slide along the corresponding bearing surfaces 412 of the rail 226 of the first spider 118. As described above with respect to FIGURE 1 the other end of each bar 116 at the second spider 120 may be supported and driven by a support or mobile flange 132, whilst the bar end 228 at the first spider 118 slides along the arm 121 of the first spider 118 as described above. That is the bars 116 may be retracted inwardly and radially within the reel as well as extended outwardly radially within the reel. By appropriately positioning and driving the mobile flanges 132 for each bar 116, the drum 114 diameter may be adjusted to increase or decrease. An adjustable drum diameter is advantageous to varying the drum diameter during pipe coiling in order to secure the pipe coil windings and the partially completed pipe coil to the drum 114 by increasing the drum diameter. It is also of an advantage to decreasing the drum diameter for a completed pipe coil in order to aid in ejecting and unloading of the completed pipe coil from the drum 114 of the coiler 110. Furthermore the operation of increasing and decreasing the drum diameter may be automated during the coiler 110 operation.

[0080] FIGURES 7 and 8 are schematic drawings / photographs in perspective view to a new pipe latch device or conformal pipe clamp 140, shown in FIGURE 1. The conformal pipe clamp 140 may be used to secure the start of the pipe end to the reel 112 of the pipe coiler 110. FIGURE 7 is a schematic diagram to a perspective view of the pipe clamp 140 and a drilling pin 712 that is also used to pin, as a lynch pin or otherwise, the pipe start end within the pipe latch/clamp 140 and to the reel 114 ready for pipe coiling. FIGURE 7 shows the pipe latch 140 in an open position ready to accept a pipe end, or conversely when releasing a completed pipe coil. Each of the jaws 714, 716 may have their inner clamping surfaces scalloped or recessed so as to be substantially conformally shaped 718 to the pipe start end so as to: minimise a distortion to the pipe start end, securely clamp the pipe start end and release the pipe start end. Regarding the ease of release, this it to facilitate ejection of the start pipe end at the end of the coiling processes.

[0081] The drilling pin 712 is preferably positioned such that its longitudinal axis is parallel to the longitudinal axis of the reel 112. The jaws 714, 716 may have a recess 720 to a jaw inner surface and / or an aperture 722 as guide-ways 720, 722 for the drilling pin. The conformal shape of the inner surfaces of the jaws and the positioning of the guide-ways 720, 722 for the drilling pin 712 are adapted to: to present opposing side walls of the pipe start end such that the drilling pin does not bind during drilling, securing and release of the pipe start end.

[0082] FIGURE 8 is to a paired pipe latch/clamp device 840 for clamping the start end of two pipes to be coiled in a paired or double arrangement. The inner surface of the clamping jaws 814, 816 of the paired pipe clamp 840 have a second conformal shaping or recess 818 to accommodate a second pipe. The paired conformal pipe clamp 840 is shown in the closed and pinned state but without a pipe end so that the drilling pin 712 within the guide-ways 720, 722 of the clamping scallops or recesses 718, 818 may be shown. Advantageously the pipe latch is shown in FIGURE 8, as for FIGURE 1, mounted to one side of the reel 112 so that the start pipe end does not interfere with a uniform coiling radius during coiling. That is, to prevent any occurrence of a bend radius less than that of the internal diameter of the completed pipe coil and the drum 114.

[0083] It will be readily appreciated that the pipe latching/clamping, pinning and release may be automated in co-operation with the haul-off device 220 and the unloading / ejection operations for the completed coil.

[0084] FIGURE 9 is a schematic diagram of a front perspective view of the rear paddle units 312, 314 shown in FIGURE 3. In FIGURE 9 an upper rear paddle 912 and a lower rear paddle 914 are shown, corresponding to the upper and lower paddle units 312, 314 of FIGURE 3. The rear paddles 912, 914 may be applied to an outer surface of the coiling pipe on the drum 114 so as to keep the pipe coil windings suitably tight and in place during automatic, intermediate strapping operations as the coiling progresses layer by layer and across the reel for a layer. In addition when the pipe coiling is completed the rear paddles 912, 914 may be used to restrain the pipe coil windings during cutting of the pipe tail end and final strapping of the pipe coil.

[0085] The rear paddles 912, 914, 312, 314 are moveable radially inwardly and outwardly with respect to the reel 112 longitudinal axis and the pipe windings as indicated by the arrows 916. The radial movement 916 being to compress the pipe coil windings as described above. The rear paddles 912, 914, 312, 314 are also moveable parallel to the reel 112 longitudinal axis in the direction of arrows 918 in order to automatically track with the pipe coiling across the drum 114. Typically the rear paddles 912, 914 are placed on the opposing side of the reel 112 to the haul-off unit 220, but also may be placed about the reel 112 depending on the particular coiler used.

[0086] Advantageously an indexing pin or indexing guide 920 is co-located with the upper paddle unit 912, 312 in order to translate parallel to the reel 112 longitudinal axis with the upper rear paddle 912. The indexing pin 920 may independently move radially to the rear paddle 912 in order to engage separately with the pipe coil windings. In use the indexing pin 920 may be used to aid in pushing or guiding a coiling pipe to an adjacent pipe coil winding during coiling as well as during automatic intermediate strapping of the partially completed pipe coil. When guiding the pipe coiling the indexing pin 920 may be independently extended radially towards the reel whilst the upper rear paddle 912 is retracted radially. For intermediate strapping the indexing pin 920 and the upper rear paddle 912 may both be extended radially towards the reel and the pipe coil windings in order to compress the pipe coil windings radially and maintain the position of the last pipe coil winding.

[0087] In addition the pin may be synchronised or otherwise controlled with respect to the haul-off 220 and reel 112 rotation to also aid in indexing the pipe in a coil layer as coiling progresses. It will be readily appreciated that the indexing pin 920 with a rear paddle 912, 914 may be positioned about the reel and coiler as appropriate for a particular coiler configuration or construction.

[0088] FIGURES 10 to 12 are schematic diagrams showing various perspective views of an automatic strapping unit 1012 for intermediate strapping of a partially completed the pipe coil and final strapping of a completed pipe coil by the coiler 110. In FIGURE 10 the position of the strapping unit 1012 and strapping channel circuit or race-way 1014 within the reel 112 of the coiler is shown. In this example the complete, closed strapping channel circuit 1014 or race-way circuit is shown in the open configuration of the reel 112 for clarity purposes and to show the retractable strapping channel 224. The internal strapping channel 138 has been shown in and described with respect to FIGURES 1 and 8. The retractable strapping channel 224 has been shown in and described with respect to FIGURE 2.

[0089] FIGURE 11 is an enlarged view of the rectangular boxed region of FIGURE 10 showing the strapping unit 1012 with the strapping channel circuit 1014. In use a drive wheel arrangement propels a strapping tape from the strapping unit 1012 along one side of an external, central strapping channel 1112, into the reel 112 via the external strapping channel 1114, within the drum 114 via the internal strapping channel 138, exiting the reel 112 via the retractable strapping channel 224 and returning to the strapping unit 1012 via the other side of the external central strapping channel 1112. It will be readily appreciated that the direction of travel of the strapping channel may be reversed.

[0090] FIGURE 12 is a perspective view of only the strapping unit 1012 with the strapping channel circuit 1014 about a cross-section of a partially completed pipe coil 1212 that may be automatically strapped. [0091] The strapping unit 1012 and strapping channel circuit may also be controlled co-operatively with the coiling process so that intermediate strapping within the coil occurs as coiling progresses as described above with respect to FIGURE 2.

[0092] When the reel 112 is in the closed configuration with the first spider 118 joined to the bars 116 of the drum, the strapping circuit 1014 may be completed by a strapping channel located with the first spider 118 than by the retractable strapping channel 224.

[0093] In addition the use of the retractable strapping channel 224 allows for a pipe coil to be strapped whilst the reel 112 of the coiler 110 is in the open

configuration with the first spider 118 separated from the drum 114. This is of particular advantage to allow for faster unloading of the completed pipe coil by simultaneously strapping and beginning the unloading sequence of a completed pipe coil. The use of retractable strapping channel 224 also allows for intermediate strapping of another partially completed pipe coil that has been started in the open configuration coiler whilst the recently completed pipe coil is completing its unloading. For example the recently completed pipe coil may be awaiting a crane and / or freight transport.

[0094] FIGURES 13 to 21 are a sequence of schematic drawings in perspective view from the front of the coiler 110 showing the ejection / unloading of the large, completed pipe coil 1312 from the reel 112 of the coiler 110. In FIGURES 13 to 21 the strapping of the completed pipe coil 1312 has been omitted to improve clarity. An example of intermediate and final strapping to a completed pipe coil is shown in FIGURE 22 below. Typically final strapping of the completed pipe coil 1312 is finished before the pipe coil unloading sequence of FIGURES 13 to 21 is started

[0095] In FIGURE 13 the just completed large pipe coil 1312 is shown in the coiler 110. The convex spreader beam 212 for lifting the pipe coil 1312 is adjacent the end support 124 of the first spider 118.

[0096] In FIGURE 14 the convex spreader beam 212 is shown raised by the lifting gantry 218 so that it may be ready to be inserted through the first spider 118 arms 121 and into the upper, inner portion of the completed pipe coil 112. The reel 112 may be rotated as appropriate so that the first spider 118 arms 121 are positioned to receive the convex spreader beam 212 between the upper arms 121. Also the support prongs 134 on the first spider 118 may be moved radially outwardly to support the inside of the pipe coil 1312 during unloading. The rear paddles 912, 914 and the indexing pin or guide 920 may also be retracted away from completed pipe coil 1312 so as not to hinder unloading. Also simultaneously or at about the same time the retractable strapping channel 224 or race-way may be retracted if need be away from the reel 112 and the completed pipe coil 1312. The conformal pipe clamp 140 or latch may now also release the pipe start end from the drum 114 of the reel 112. That is the drilling pin 712 is withdrawn from the pipe start end and the jaws 714, 716, 814, 816 opened.

[0097] In FIGURE 15 the lifting table 142 is shown raised to support the base or lower portion of the pipe coil 1312. The two moveable flaps 146 may also be raised so as to further support and conform the lifting table 142 to the lower portion of the coil 1312. The lifting table 142 may rise with a contact force of approximately 250 kg or less so or as appropriate so as to not disturb the pipe coil windings or distort the wound pipe. Once the lift table 142 is in the appropriate supporting position and configuration the lifting table 142 may be hydraulically locked in position with a load carrying capacity of at least approximately 10 tonnes.

[0098] Simultaneously or shortly after the lifting table 142 is supporting the pipe coil 1312, the multiple circumferential bars 116 may optionally retract radially inwardly to reduce the drum 114 diameter in order to facilitate unloading of the pipe coil 1312.

[0099] In FIGURE 16 the convex spreader beam 212is moved into position within the completed pipe coil 1312 by passing the spreader beam 212 between the first spider 118 arms 121 on one side of the reel 112 as the removable first spider 118 separates from the drum 114 of the reel 112. The convex spreader beam 212 may be placed within the completed coil 1312 to support the upper part of the coil 1312 during unloading from the coiler and to lift the coil 1312 away from the coiler 110. To aid in unloading the completed pipe coil 1312 from the drum 114 the ejectors 136 on each bar 116 may push the pipe coil 1312 along the drum 114 towards the first spider 118 as the first spider moves away from the drum 114. The ejectors 136 may also be programmable in their operation, for example with respect to the correct orientation of the reel spider arms 121 to eject or push the completed pipe coil 1312 off the drum 114. Simultaneously as shown in FIGURE 16 the raised lifting table 142 may simultaneously traverse with the end support 124 to support the pipe coil 1312 as it moves off and away from the drum 114.

[00100] Alternatively or in addition the convex spreader beam 212 may be mounted on an extendable beam or ram so that prior to or with the first spider 118 separation from the druml 14 , the convex spreader beam 212 may be extended towards the first spider 118 supporting the completed coil 1312.

[00101] In FIGURE 17 the completed, large pipe coil 1312 is shown removed from the drum 114 and second spider 120 whilst still being supported by the support prongs 134 on the first spider 118 and the lifting table 142. The convex spreader beam 212 is shown spanning the inside width of the coil 1312, the lifting eyes of the convex spreader beam 212 being outside the width of the pipe coil 1312.

[00102] At FIGURE 17 of the unloading sequence a new pipe coiling may be commenced on the drum 112 with the second spider 120. That is the ejectors 136 may be moved back to the second spider 120 and a new pipe start end fed by the haul-off device 220 to the conformal pipe clamp / latch 140 for securing to the drum 114. Coiling of another pipe coil may then commence with the reel 112 in an open configuration.

[00103] In FIGURE 18 the first spider 118 is shown removed from the pipe coil 1312. The first spider 118 is removed by retracting radially and inwardly the support prongs 134 on the first spider 118 away from the inside of the pipe coil 1312 and then moving the first spider 118 away from the pipe coil 1312 and lifting table 142. Simultaneously or at about the same time the convex spreader beam 212 may be raised by the lifting gantry 218 to support and maintain the stability of the pipe coil.

[00104] In FIGURE 19 the pipe coil 1312 is shown being lifted up and away from the coiler 110 by the convex spreader beam 212.

[00105] In FIGURE 20 the coiler is shown without the removed pipe coil and with the lifting table 142 lowered. The first spider 118 has been moved back towards the drum 114 to re-form the reel 112 in the closed configuration. As mentioned earlier with respect to FIGURE 17 of the unloading sequence, a new pipe coiling may have been commenced already as the first spider 118 is moving back to engage with the drum 114. The pipe coiling may be interrupted briefly to allow the first spider 118 to engage with the drum 114 so that the single assembly of the rotating reel 112 of two spiders 118, 120 and drum 114 may be re-formed. That is the closed configuration of the reel 112 is done so that pipe coiling may continue to the desired pipe coil size.

[00106] In FIGURE 21 the closed configuration of reel and the coiler

110 is shown. The coiler is ready to commence pipe coiling, if not already

commenced as described above with respect to FIGURE 17.

[00107] It will be readily appreciated that in the above described unloading sequence of FIGURES 13 to 21, that some of the steps may vary in location in the unloading sequence as determined by a person skilled in the art of handling and coiling of plastic pipe.

[00108] FIGURE 22 is a schematic perspective view diagram / photograph showing an overhead crane lifting a completed pipe coil 2212 into a cradle or stand 2214. The cradle 2214 is described in PCT Patent Application number PCT/AU2017/050184 as referenced earlier. FIGURE 22 also shows examples of the intermediate 2216 and final strapping 2218 applied to these very wide and large pipe coils so that the pipe coil 2212 may be moved and transported without distortion.

[00109] In FIGURE 2 the haul-off unit 220 is shown in a configuration for single pipe. When paired pipe is being coiled, opposing ski like projections or guides may be mounted above and below the entry rollers of the haul off unit 220 in order to guide and support the paired pipe into the haul-off unit / pulling device 220. The ski-like guides from the haul-off unit 220 may also aid in supporting and guiding the pipe as the haul-off unit 220 moves horizontally backwards and forwards across the reel 112 accumulating the coiled pipe.

[00110] FIGURES 23 and 24 are schematic diagrams / photographs in perspective view of examples of the two ski- like guides 2312, 2412 with mounting brackets 2316 detached from the haul-off unit 220. FIGURE 23 shows an upper, outer view of the ski-like guide whilst FIGURE 24 shows an inner view of the pipe guiding surface of the ski-like guide 2412. Both guides 2312, 2412 are foil like with a curved entry end 2314 directed towards the entering, paired pipe from the pipe extrusion lines. The ski-like guides 2312, 2412 are of a particular advantage in guiding and controlling the tail end of the pipe towards the end of completing the pipe coil.

[00111] In order to accommodate variations in speed between the extrusion line and the pipe coiler 110 up-take of pipe, a dancing arm or adjustable arm ("ballerina") may be used to provide a bend in the extruded pipe length between the pipe extruder line and the haul-off unit 220 of the coiler 110. A bend in the pipe may be increased or decreased adaptively in response to variations in extrusion line pipe output, pipe coiling speed or throughput by the coiler during pipe coiling as well as during unloading if need be. For example intermittently the coiler 110 may stop for intermediate strapping or for other reasons: in response the dancing arm may increase a bend in a pipe length between the extrusion line and the coiler so as accumulate more pipe length prior to the coiler. Once the coiler has resumed coiling the dancing or adjustable arm may allow the bend in the pipe length to decrease in order to provide more pipe length than the extrusion line may supply. That is the dancing arm arrangement is used to provide a buffer between extrusion line output and coiler 110 input for pipe. Or in other words speed synchronisation between the extrusion line pipe output and the coiler pipe input.

[00112] Surprisingly the inventors have found that a dancer arm or adjustable arm operating horizontally on the factory floor performs better than the typical vertically operating dancer arms of the prior art. A horizontally operating dancer arm is of a particular advantage for larger pipe diameters and thicker walled pipe that may be coiled by the invention.

[00113] In summary the pipe coiling invention/s described above enable a fully automatic and controllable pipe coiler 110. The new pipe coiler 110 with the features of the above may have fully automatic, control and regulation (feedback control for example) to pipe clamping at start-up, automatic coiling, automatic intermediate and final strapping of the full width coil and automatic ejection / unloading of the completed pipe coil. In addition the automated and simultaneous restart of pipe coiling during the unloading of a previously completed pipe coil. That is no or minimal manual or human involvement to manual clamping of the pipe at startup, no drums or reels for the pipe coil to be transported or freighted upon in comparison to prior art coilers, particularly of larger pipe diameters, which may have large or continuous manual input required throughout the coiling and unloading process.

[00114] It will be readily appreciated that the above apparatus, techniques and apparatus may be readily adapted for use to other pipe coiling apparatus and processes.

[00115] In this specification, terms denoting direction, such as vertical, up, down, left, right etc. or rotation, should be taken to refer to the directions or rotations relative to the corresponding drawing rather than to absolute directions or rotations unless the context require otherwise.

[00116] Although the invention has been herein shown and described in what is conceived to be the most practical and preferred embodiments, it is recognized that departures can be made within the scope of the invention, which are not to be limited to the details described herein but are to be accorded the full scope of the appended claims so as to embrace any and all equivalent assemblies, devices, apparatus, articles, compositions, methods, processes and techniques.

[00117] In this specification, the word "comprising" is to be understood in its "open" sense, that is, in the sense of "including", and thus not limited to its "closed" sense, that is the sense of "consisting only of. A corresponding meaning is to be attributed to the corresponding words "comprise, comprised and comprises" where they appear.