TECHNICAL ARTICLE:
| Complete Software Management for Tube and Pipe System Design and Production |
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| By: G A Nieweg & G Schulze-Dürr, 3R Solutions, Germany | ||||||||||||
Introduction In order to achieve the complete and efficient automation and work process of tube production on a tube line, G A Nieweg and 3R Software Solutions have developed a range of design software systems to aid areas of pipeline construction, simulation and tube and pipe production. Utilising this interlinking software range for the design, layout and management of pipelines and tube and pipe production, ideas can be checked prior to production, with programs minimising mistakes in calculation, breaking of tools (e.g at the collision of a bending machine), collisions of inter-connecting pipes and other corrections. Analysis and conclusions are essential in the run-up to production, as actual production rates can then be shorter if the prior research is effective. The pre-production becomes more precise and gains in excess of 90 per cent of the whole tube-production. Software – intended for a special solution – also often contains additional benefits in speed, quality and integration period. There are for all areas of tube production – planning, construction, production, mechanical control, fitting and review – a comprehensive set of programs. Each piece of software contains one or more sub-programs to allow for different tasks. Bigger systems provide a general solution, as they assist the planning and construction as well as the overall production. Interfaces between the single programs are no longer necessary, as a system with an integrated data bank can retrieve all information just from the data of the isometry, to analyse and realise targets. Production Requirements and Software Solutions It is constructive to take a view of a model company where each area of tube production appears to be unconnected. Tubes are neither straight or round, nor is welding always clean, a factor caused by rust, tinder, wax or grease where mistakes can happen. To clean before or after the cut is a conflict of decisions. According to the purchase quality it is advisable to clean or shot-blast the tubes. If the tubes are then treated chemically, the conditions from the authorities are very high. Clean tubes can make the work in the company easier, improving the quality and increasing the throughput. The warehouse (with material for one week) should be easily loaded, so that the supplier cannot calculate waiting time. All of these aspects must be analysed and balanced and software is the best tool to achieve this. Using this software, the production course criterions assessed include quality of products, price, delivery time, actual delivery duration and flexibility. Potential sources of error can be eliminated at an early stage. Especially effective are continuous systems under Windows, from pattern CAP, construction CAD, production control with machinery control CAM, and fitting supervision CAQ.
Mapping and Analysing the Pipeline Construction Area: RoniR2D The software RoniR2D enables the creation of a functioning diagram and a plan for the work area: mapping a pipeline system, calculating measurements, gathering production criteria, and setting the production schedule. Using this simple, user-friendly and functional software, the pattern-erection – in conjunction with the RoNi-data bank – simply sets up symbols and tubes in a true to scale representation. Via a link up to the data bank, sufficient erection of material can be made much quicker. The classification of the material to be used makes it possible to filter diagrams into nominal values and check systems for feasibility, analysing the viability of the specified material and either accepting or rejecting it. In addition, planning lists of the pieces required can also be generated, filtered according to nominal values and sections. The general flow of all data to the following systems is thus guaranteed. Modifications can be achieved through all systems. The DXF import function enables the user to establish a plan or pattern with reference to the working area. RoniR2D uses an integrated DXF file system to produce a scale plan of the working area. The DXF drawing shows the sections dissected and the scale can be defined according to requirements and adapted to the technical drawing. Symbols for joints and pieces can be generated and placed at many connecting points as required for immediate use. RoniR2D establishes lists of items for planning, with DXF import operating as an exact platform to aid construction in the very early stages. The list of items (pieces) is automatically sub-divided according to the pipes or tubes at the place of work, according to the fitting elements and processing. Materials for the pre-processing phase can then be directly carried over into the RoniCAD isometric function. In terms of construction, item lists can, for instance, be produced for the individual departments, decks and for the entire ship. The amounts can be displayed in pieces, metres and kilograms. Thus mistakes from duplication or inadmissible material, for example, is prevented. All the lists produced can be, if needed, exported into other systems.
The linking of the individual systems by means of a joint data bank makes it possible to carry out a fast and efficient change in every direction. Both for the functional and construction aspects, changes can automatically be seen in all sectors. All the programmes recognise the particular processing status of each component part. Any changes and consequences can then be transferred and verified within complementary software: RoniCAD, KOLLI, RAMP and Roni3D. 2D and 3D Construction Platform: RoniCAD Developed especially for the high demands of the tube and pipe industry, plants, shipbuilding and the motor vehicle industry, RoniCAD is a high-performance 2D- and 3D-construction platform with data bank. The system is applied in tandem with the isometric system and also applied as a coordinating programme with its 3D module. Isometric drawings and 3D volume models can be displayed simultaneously. RoniCAD establishes the processability of the drawings during the construction phase. It can operate with the standard data bank systems both as a network version and also as an individual version. The system runs with Windows-NT (from Service Pack5), Windows 2000 and Windows XP.
3R’s KOLLI5 (or KOLLI6) software is fully integrated so complete constructions can be tested in a fast and simple way if it is possible to produce them. The logical test checks isometrics if they are wrong or missing component parts. RoniCAD export interfaces include MS-Excel, Word, Projekt, AutoCAD and Unigraphics (Isogen). The importing interfaces include AutoCAD (DXF), Bravo, CATIA4&5, Tribon V1 and V2, MEDUSA and Unigraphics (Isogen). RoniCAD creates parts lists, calculation points, material requirements, sawing lists, bending lists, in addition to weld seam and point calculation and assessment of work time, all data which can then be handed over to 3R’s RAMP software. Isometrics can be created proportionally as well as with no scale, so pipelines can be represented with elements laying narrow in one place in a clearly arranged, optical manner. As a result of the optimised pipe lengths and materials the remaining pipe lengths are minimised. The cut-off pipes are automatically given labels, including barcode information, at the cutting work stage. Using a scanner at the Data Processing station the bending machine can automatically (using the bar codes), put them into the correct bending record sheet and transfer this to the CNC bending machine. At the workplace of the orbital welding machine the isometrics are made visual and a new status is put into the data bank. With another scanner at the data processing station the pressure samples are loaded into the corresponding drawings, the work sheets are made visual and the new status is entered into the data bank. RoniCAD establishes, in the preliminary phase, the maximum expansion and the weight of the given part pipe piece. Optimised cutting lists, work sheets, bending lists, calculation of transport amount and weights are all drawn up in the system. The workpieces are then processed using the data in a time controlled material flow, through the CNC cutting machines, CNC bending/forming machines, and workplace orbital welding, with continual updating of the data bank. Simulation Software Verifies Part List Creation: KOLLI and ROBA To aid and complement the RoniCAD software, KOLLI and ROBA is a range of simulation software for the analysis of processability of pipes and tubes. KOLLI assesses the entire spectrum of the required data for cold and warm bending of pipes and tubes on the many different types of bending and forming machines. The availability of the tools required and the resulting minimum lengths are automatically checked. The stretching and pliability of the various materials is calculated with the KOLLI bending lists and cutting lengths. Parameters such as speed, pressure, bending momentum, oval shaping and weaknesses are also assessed. The input of the different isometric data is carried out with Cartesian coordinates or directly from bending/forming values (thrust, turning and bending).
Nieweg and 3R work very closely with users and the various manufacturers of bending/forming work benches and in this way the KOLLI import and export interfaces have been adapted for the well-known construction systems and the most popular tube bending machines. The different SPS-systems can be directly guided with bending and forming data. System Optimisation and Information Analysis Whether it is tubes or pipes, production activities, materials or the management of human resources, the RAMP system software allows the import of tube isometrics from Roni or unknown systems. RAMP is a program for production control and it erects production-packages for a special period. Filters for contract/order, job, date, building group or model tube make the individual erection of production packages possible. It sorts and optimises for different machinery, and is able to control the whole machinery in the workshop or give the worker the appropriate spreadsheet. RAMP supplies optimised cutting lists, bending, flange welding automation, and direct operating of the CNC-machines – saws, bending machines, flange welding machine, tube burn machine, pipe or tube storage warehousing. This avoids waste and incorrect input, and achieves huge time saving on the individual machines. In each processing step there is the possibility to provide lists of pieces, technical drawings and work sheets including all the information needed for the processing monitoring. In combination with Roni software, RAMP also has a 3D capability, enabling real 3D views of the step-by-step processing levels.
The software should only be used from one position. This central office has all data alteration rights of the packages, while further users can view the data via a network of PCs. It makes suggestions for scheduling and the production target, and calculates the state of production. RAMP enables variants for different nominal widths and each element in the data bank. The data output is in ASCII-format and a neutral median line is output too. RAMP permits a listing of all the material data and piece numbers by means of the different filter criteria. Material requirements of a complete order, or a section of it, or a certain time interval can be called up and presented within seconds. Various diagram sizes assure an optimal overview. The established amounts can be exported in various programmes, including MS-Word, MS-Excel, MS-Project and SAP/R3.
Tube and Pipe Storage Management The 3R-system STORE serves as an efficient planning system for guidelines and capacities of the cutting stations within a tube or pipe workshop. All the information is stored in a data bank system, or if preferred in a sql data file. Statistical analysis of material consumption, orders or related data can be called up at the push of a button. In this way the time management for the pipe pieces can be planned and organised according to the capacities of the cutting machines. STORE imports tube or pipe lengths with a range of information from the KOLLI system or any other construction system, including order, technical drawing number, article number/material, exterior diameter, wall thickness, length of tube or pipe, number of pieces, and date for processing. A further module in the STORE system presents the warehouse administration for pipes or tubes. Delivered pipe pieces can be accepted into storage including the lot number. The order and project administration is prepared as a work package for the workshop. Conclusion The planning, construction, pre-production and fitting of tubes is becoming an increasingly fast and developed science, with companies wishing to achieve efficiency and cost savings from a great system. Many companies are preparing to operate wholly via utilisation of computers. For this step a multi-faceted software program is required, offering mechanical engineering, electricity management, building of apparatus, and house building. Therefore it is essential to employ a system that can manage tube production, acting as an interface to other systems, with all systems compatible and general from planning to fitting.
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