阅读说明：本技术 用于形成管道的管状加强件的机器和相关方法 (Machine for forming tubular reinforcements of ducts and relative method ) 是由 R·P·斯蒂坎 O·S·艾尔维斯 L·G·珀勒斯 于 2018-12-19 设计创作，主要内容包括：一种机器(100),所述机器包括：﹣第一进给器(112),其能够解绕第一带材(31)；﹣成型机设备(110),其包括上游成型台(122A-122G),上游成型台能够使第一带材(31)成型以形成预成型的第一带材(31)；﹣第二进给器(114),其能够解绕第二带材(48),所述第二带材(48)是扁平带材；所述成型机设备(110)包括：﹣中间连结台(124),其能够从第二进给器(114)接收作为扁平带材的第二带材(48)并且能够连结预形成的第一带材(31)和扁平的第二带材(48)；和﹣至少下游成型台(126A至126C),其构造为使得从所述中间连结台(124)接收的第一带材(31)和第二带材(48)共同成型并且形成组合的成型条(196)。(A machine (100), comprising: -a first feeder (112) able to unwind a first strip (31); -a former device (110) comprising an upstream forming station (122A-122G) capable of forming a first strip (31) to form a pre-formed first strip (31); -a second feeder (114) capable of unwinding a second strip (48), said second strip (48) being a flat strip; the molding machine apparatus (110) includes: -an intermediate joining station (124) able to receive the second strip (48) as a flat strip from the second feeder (114) and to join the first pre-formed strip (31) and the flat second strip (48); and-at least a downstream forming station (126A to 126C) configured to jointly form the first and second strips (31, 48) received from the intermediate joining station (124) and to form a combined forming strip (196).)

1. A machine (100) for forming a tubular reinforcement (29) of a duct (10), comprising:

-a first feeder (112) able to unwind a first strip (31);

-a forming machine apparatus (110) comprising at least an upstream forming station (122A-122G) able to receive said first tape (31) from said first feeder (112) and able to form said first tape (31) to form a pre-formed first tape (31);

-a second feeder (114) capable of unwinding a second strip (48), said second strip (48) being a flat strip;

characterized in that the former device (110) comprises:

-an intermediate joining station (124) able to receive the second strip (48) as a flat strip from the second feeder (114) and to join the first and second pre-formed strips (31, 48); and

-at least a downstream forming station (126A-126C) configured to co-form and form a combined forming strip (196) the first and second strip materials (31, 48) received from the intermediate joining station (124).

2. The machine (100) according to claim 1, wherein the intermediate joining station (124) comprises at least a redirecting first roller (130) for redirecting the second strip (48) from the second feeder (114) to at least one of the downstream forming stations (126A-126C), the second strip (48) remaining as a flat strip, the intermediate joining station (124) comprising a second roller (132) for supporting the pre-shaped first strip (31).

3. The machine (100) of any of claims 1 to 2, wherein each forming station (122A-122G; 126A-126C) has at least two opposing rollers (130, 132) defining a forming gap (134) therebetween.

4. Machine (100) according to claim 3, wherein at least a downstream forming station (126A-126C) has a forming interspace (134) comprising at least a zone (168) for jointly deforming the first strip (31) and the second strip (48) and at least a zone (170) for deforming only the first strip (31) and not the second strip (48).

5. Machine (100) according to claim 4, wherein the forming interspace (134) of the at least downstream forming station (126A-126C) comprises at least a zone (172) for maintaining the shape of a zone of the second strip (48).

6. Machine (100) according to claim 5, wherein a cross section of said area (172) for shape retention, in a plane (P) containing the rotation axes of said opposite rollers (130, 132), is delimited by opposite flat zones, said second strip (48) being kept flat in said area (172) for shape retention.

7. Machine (100) according to any one of claims 3 to 6, wherein at least one of said opposite rollers (130; 132) defines a lateral deformation surface for bending an edge of said first strip (31).

8. Machine (100) according to any one of the preceding claims, wherein said second feeder (114) comprises: a second strip unwinder (184) onto which the second flat strip (48) is wound; at least one second strip guide roller (186A-186C) for orienting the second strip (48) paid out from the second strip unwinder (184) toward the intermediate joining station (124).

9. Machine according to claim 8, wherein the second feeder (114) comprises a brake (187) advantageously interposed between the second tape unwinder (184) and the intermediate joining station (124) in order to control the feeding speed of the second tape (48) in the intermediate joining station (124).

10. The machine (100) according to any one of claims 8 or 9, wherein the second feeder (114) comprises a pair of opposite registration rollers (188) to guide the second strip (48) to the intermediate joining station (124) in a predetermined feeding direction (G-G').

11. Machine (100) according to any one of the preceding claims, comprising a winding device able to wind the combined profiled strip (196) helically on a cylindrical outer surface (104) to form the tubular reinforcement (29).

12. Machine (100) according to claim 11, wherein the winding apparatus comprises a rotary support (106) mounted so as to be rotatable about a winding axis (E-E') defined by the cylindrical outer surface (104), the rotary table carrying the first feeder (112), the second feeder (114) and the molding machine apparatus (110).

13. A method for forming a tubular reinforcement (29) for a pipeline (10), the method comprising the steps of:

-unwinding a first tape (31) from a first feeder (112);

-feeding said first strip (31) from said first feeder (112) to at least an upstream forming station (122A-122G) of a forming machine apparatus (110) so as to form a pre-formed first strip (31);

-unwinding a second strip (48) from a second feeder (114), said second strip (48) being a flat strip;

the method is characterized in that:

-feeding the second strip (48) as flat strip from the second feeder (114) into an intermediate joining station (124) of the forming machine apparatus (110) and joining the first and second pre-formed strips (31, 48) in the intermediate joining station (124);

-co-forming said first strip material (31) and said second strip material (48) received from said intermediate joining station (124) in at least a downstream forming station (126A-126C) so as to form a combined forming strip (196).

14. The method of claim 13, wherein each forming station (122A-122G; 126A-126C) has at least two opposing rollers (130, 132) defining a forming gap (134) therebetween,

co-forming the first strip (31) and the second strip (48) in at least a downstream forming station (126A-126C) comprises co-deforming the first strip (31) and the second strip (48) in at least one region (168) for co-deforming in the void (134), and deforming only the first strip (31) and not the second strip (48) in at least one region (170) for deforming only the first strip (31) in the void (134).

15. The method of any of claims 13 or 14, comprising helically winding the combined profiled strip (196) around a cylindrical outer surface (104) to form the tubular reinforcement (29).

Technical Field

The invention relates to a machine for forming a tubular reinforcement for a duct, comprising:

-a first feeder capable of unwinding a first strip;

-a forming machine apparatus comprising at least an upstream forming station capable of receiving a first strip from a first feeder and forming the first strip to form a pre-formed first strip;

-a second feeder capable of unwinding a second strip, said second strip being a flat strip.

The pipe is preferably a flexible pipe of the non-bonded type intended for transporting hydrocarbons through a body of water such as an ocean, sea, lake or river.

Background

Such flexible pipes are manufactured, for example, according to the standards API 17J (specification for unbonded flexible pipes, fourth edition, 5 months 2014) and API RP 17B (recommended practice technology for flexible pipes, fifth edition, 3 months 2014) established by the american petroleum institute.

The conduit is typically formed from an assembly of concentric and stacked layers. A pipe is considered "unbonded" if at least one layer of the pipe is able to move longitudinally relative to an adjacent layer when the pipe is flexed. In particular, a non-bonded pipe is a pipe that does not have any bonding material connecting the layers forming the pipe.

The pipeline is typically positioned through the body of water between a bottom assembly intended to collect the fluid produced at the bottom of the body of water and a floating or fixed surface assembly intended to collect and distribute the fluid. The surface assembly may be a semi-submersible platform, FPSO or other floating or fixed assembly.

In some cases, the flexible pipe includes an inner carcass layer (carcas) positioned within the pressure jacket. The carcass layer prevents collapse contraction of the pressure jacket under external pressure, such as when the internal passage is depressurized for circulation of a fluid defined by the pressure jacket.

The inner carcass layer is typically formed from a profiled metal strip which is wound into a spiral shape. The turns of the strip interlock with each other. The turns define between them a helical gap which opens radially inwards into the central channel for circulation of the fluid.

Thus, the inner surface of the carcass layer has a series of depressions and elevations in the axial direction. The pipe is then generally referred to as a "rough pipe".

In some cases, the circulation of the fluid along the carcass layer is disturbed by the raised/recessed portions defined on the carcass layer by the helical gaps.

Such flow disturbances are sometimes considered to be the cause of vibration phenomena in the flexible pipe, and even the cause of pulsations caused by the circulation of the fluid when resonance occurs ("flow-induced pulsations" or "ringing").

To overcome this problem, it is known to manufacture flexible pipe without an inner carcass layer. These pipes have smooth surfaces ("smooth pipes"), but are subject to collapse contraction under reduced pressure.

Another solution to this problem is disclosed in WO 2014/135906. In this document, the flexible pipe comprises a carcass layer, wherein the helical gaps present between the different turns of the carcass layer are closed by an S-shaped profiled strip and are inserted into the profiled interlocking strip.

Such a carcass layer is efficient in reducing flow-induced vibrations. However, it is rather complicated to manufacture.

In fact, two different forming machines are required to form the first strip forming the interlocking carcass layers on the one hand and the strip forming the S-shaped inserts (which close the gaps of the interlocking carcass layers) on the other hand.

After each strip is shaped separately, a joining apparatus is used to form a joined shaped strip that is helically wound to form the tubular reinforcement.

Thus, the machines used to form the carcass layer are heavy and complex to use. In particular, the joining of the first profiled strip to the second profiled strip must be performed very precisely, which requires fine-tuning of the machine.

Disclosure of Invention

One purpose of the present invention is therefore to obtain a machine capable of forming a tubular reinforcement for a pipe in which the risk of vibrations and/or even pulsations occurring is limited, which is compact and easy to operate.

To this end, the subject of the invention is a machine as described above, characterized in that the molding-machine plant comprises:

-an intermediate joining station able to receive the second strip as a flat strip from the second feeder and able to join the first and second pre-formed strips; and

-at least a downstream forming station configured to co-form the first and second strip materials received from the intermediate joining station and form a combined forming strip.

The machine according to the invention may comprise one or more of the following features, taken alone or according to any technically feasible combination:

-the intermediate joining station comprises at least a redirected first roller for redirecting a second strip from the second feeder to at least one downstream forming station, said second strip remaining as a flat strip, the intermediate joining station comprising a second roller for supporting the pre-formed first strip;

-each forming station has at least two opposed rollers defining a forming gap therebetween;

-at least the downstream forming station has a forming void comprising: at least one region for co-deforming the first strip and the second strip; and at least one region for deforming only the first strip material and not the second strip material;

-the forming void of at least the downstream forming station comprises at least one area for maintaining the shape of the area of the second strip material;

-a cross-section of said area for shape retention, in a plane containing the axis of rotation of said opposed rollers, is delimited by opposed flat bands, the second strip material remaining flat in the area for shape retention;

-at least one of said opposed rollers defines a lateral deformation surface for bending an edge of the first tape;

-the second feeder comprises: a second tape unwinder around which a flat second tape is wound; at least one second tape guide roller for orienting a second tape paid out from the second tape unwinder toward the intermediate joining station;

-the second feeder comprises a brake, advantageously interposed between the second tape unwinder and the intermediate joining station, in order to control the feeding speed of the second tape in the intermediate joining station;

-the second feeder comprises a pair of opposite registration rollers for guiding the second strip to the intermediate joining station with a predetermined feeding direction;

-the machine comprises a winding device able to wind the combined shaped bars helically on the cylindrical outer surface to form the tubular reinforcement;

-the winding apparatus comprises a rotary support mounted so as to be rotatable about a winding axis defined by said cylindrical outer surface, the rotary table carrying said first feeder, said second feeder and said forming machine apparatus.

The invention also relates to a method for forming a tubular reinforcement for a pipe, comprising the steps of:

-unwinding a first strip from a first feeder;

-feeding a first strip from a first feeder to at least an upstream forming station of a forming machine apparatus so as to form a pre-formed first strip;

-unwinding a second strip from a second feeder, said second strip being a flat strip;

the method is characterized in that:

-feeding a second strip as a flat strip from a second feeder into an intermediate joining station of the forming machine apparatus and joining the pre-formed first strip and the flat second strip in the intermediate joining station;

-co-forming the first and second strips received from the intermediate joining station in at least a downstream forming station so as to form a combined forming strip.

The method according to the invention may comprise one or more of the following features, taken alone or according to any technically feasible combination:

-each forming station has at least two opposed rollers defining a forming gap therebetween,

co-forming the first and second strips in at least a downstream forming station comprises co-deforming the first and second strips in at least one region for co-deforming in the void, while deforming only the first strip and not the second strip in at least a region for deforming only the first strip in the void;

-the method comprises helically winding the combined shaped strip on the cylindrical outer surface to form the tubular reinforcement.

Drawings

The invention will be better understood on the basis of the following description, given by way of example only and with reference to the accompanying drawings, in which:

figure 1 is a perspective view, partly in section, of a central section of a first flexible pipe made using a method according to the invention;

figure 2 is a partial cross-sectional view, taken along the axial mid-plane of the detail of the pipe of figure 1, showing the carcass layer and the insert positioned in the gap of the carcass layer;

figure 3 is a detail view of the pipe of figure 2, showing a relaxed S-shaped cross-section of the insert;

figure 4 is a front schematic view of a first machine for forming the carcass layer of figure 2;

figures 5 to 7 are cross-sectional views of the forming rollers of the successive upstream forming station of the first strip in the machine of figure 3;

figure 8 is a view similar to figure 5 of an intermediate joining station of the machine of figure 3 for joining a first preformed strip with a second flat strip;

figures 9 to 10 are views, similar to figure 5, of the forming rollers of successive downstream bonding stations of the first and second strips in the machine of figure 3;

fig. 11 is a view similar to fig. 3, showing an alternative L-shaped cross-section of the insert.

Detailed Description

In the following, the terms "outer" and "inner" are generally understood radially with respect to the axis a-a ' of the conduit, the term "outer" being understood as radially further away from the axis a-a ', the term "inner" extending relatively and radially closer to the axis a-a ' of the conduit.

Fig. 1 partially shows a first flexible pipe 10.

Flexible pipe 10 includes a central segment 12. Which includes an end piece (not visible) at each axial end of the central section 12.

Referring to fig. 1, the pipe 10 defines a central passage 16 for circulation of a fluid, preferably a petroleum fluid. The central channel 16 extends along an axis a-a' between the upstream and downstream ends of the duct 10.

The diameter of the central channel is advantageously in the range 15cm to 60 cm.

The flexible pipe 10 is intended to be positioned through a body of water (not shown) in a facility for producing fluids, which are in particular hydrocarbons.

The water is for example a lake, sea or ocean. The depth of the body of water perpendicular to the surface facility is typically between 15m and 3000 m.

The surface facility is for example a surface base, a semi-submersible platform, a vertical buoy, an unloading buoy or a vessel such as an FPSO (floating production storage) or FLNG (floating liquefied natural gas).

Alternatively, the surface installation is a fixed rigid structure in the form of a hull or a swinging structure fixed under the sea surface, such as a TLP (tension leg platform).

Flexible pipe 10 is preferably a "non-bonded" pipe. At least two adjacent layers of flexible pipe 10 are free to move longitudinally relative to each other during flexing of pipe 10.

Advantageously, all layers of flexible pipe 10 are free to move relative to each other. Such pipes are described, for example, in the american petroleum institute established standardized documents API 17J (for the non-bonded flexible pipe specification, fourth edition, month 5 2014) and API RP 17B (recommended implementation technology for flexible pipes, fifth edition, month 3 2014).

As shown in fig. 1, the duct 10 defines, about the axis a-a', a plurality of concentric layers extending continuously along the central section 12 until the end members are located at the ends of the duct.

According to the invention, the pipe 10 comprises at least one first tubular sheath 20 based on a polymeric material, which advantageously constitutes a pressure sheath.

The pipe 10 further comprises at least one tensile armour layer 24, 25 positioned externally with respect to the first sheath 20 forming the pressure sheath.

The duct 10 further comprises: an inner carcass layer 26 positioned inside the pressure jacket 20, a pressure shield (pressure) 27 optionally interposed between the pressure jacket 20 and the tensile armour layers 24, 25, and an outer jacket 30 intended for protecting the pipe 10.

In accordance with the present invention, the duct 10 also includes an insert 28 having a relaxed S-shaped cross-section, the insert 28 being positioned to be supported internally on the inner carcass layer 26. In a variant, the insert 28 has a T-or L-shape (see fig. 11).

The inner carcass layer 26 and the insert 28 together form a tubular reinforcement 29 of the pipe 10.

In a known manner, the pressure jacket 20 is intended to tightly confine the fluid conveyed in the channel 16. The pressure jacket is formed of a polymeric material, for example based on a polyolefin such as polyethylene, based on a polyamide such as PA11 or PA12, or based on a fluorinated polymer such as polyvinylidene fluoride (PVDF).

The thickness of the pressure jacket 20 is for example between 5mm and 20 mm.

As shown in fig. 2, the carcass layer 26 is here formed by a spirally wound metallic first profiled strip 31. Successive turns of the strip material 31 are bound to each other.

The thickness of the strip 31 is advantageously between 0.8mm and 3.5mm and the width is advantageously between 40mm and 140 mm.

The main function of the carcass layer 26 is to absorb the radial forces of the extrusion.

The carcass layer 26 is positioned inside the pressure jacket 20. It can come into contact with the fluid circulating in the pressure jacket 20.

The helical winding of the first profiled strip 31 forming the carcass layer 26 has a short pitch, i.e. it has a helix angle close to 90 ° in absolute value, typically between 75 ° and 90 °.

The first strip 31 has two edges which are longitudinally curved back over a central area. As shown in fig. 2, which defines a plurality of binding turns having a closed and flattened S-shaped cross-section. The first strip 31 has a substantially constant thickness e 1.

The closed S-shaped cross section of each turn of the carcass layer 26, from right to left and parallel to the axis a-a' in fig. 2, comprises, in succession, an inner U-shaped portion 32, an inclined intermediate portion 34 and, in proximity to the free end thereof, an outer U-shaped portion 36, a supporting wave-shaped piece 38, generally designated by the term "short joint".

The inner portion 32 of each turn of the first tape 31 is bent back with respect to the inclined portion 34 outwardly away from the central axis a-a' towards the intermediate portion 34. Said inner portion defines a U-shaped cross-section extending parallel to the a-a' axis and open facing the inclined portion 34.

The distance between the two legs of the U is typically twice the thickness of the strip 31, but may be larger. The legs of the U are typically 6mm to 12mm in length.

The angle of the inclined intermediate portion 34 is generally comprised between 10 ° and 20 ° with respect to a radial axis perpendicular to the axis a-a'.

The outer portion 36 of the adjacent turn is partially joined into the inner portion 32 with the support wave 38 interposed between the branches of the U.

The inner portion 32 defines an inner surface 39 lying on the cylindrical envelope of the axis a-a'.

The outer portion 36 also defines a U-shaped cross-section extending parallel to the a-a' axis and opening towards the inclined portion 34.

The outer portion 36 of each turn is curved back towards the central axis a-a', towards the intermediate portion 34, inwards with respect to the inclined portion 34. The outer portion 36 and support wave 38 of that cross-section are received into the inner portion 32 of the adjacent cross-section and partially cover the inner portion 32 of the adjacent cross-section externally.

The width and length of the support wave 38 is typically between 1mm and 5 mm.

For each turn, the intermediate portion 34, the outer portion 36 and the inner portion 32 of the adjacent cross-section bound an inner gap 40 that partially or completely defines the axial play of the carcass layer 26.

The gap 40 is radially open towards the central axis a-a'. For each turn, said gap opens inwardly towards axis a-a' between inner surfaces 39 of inner portions 32 of two adjacent turns.

Externally, the gap 40 is closed by the outer portion 36 and laterally by the intermediate portion 34 of the turn and the inner portion 32 of the adjacent turn.

Thus, the gap 40 extends continuously according to a helix along the pitch P1 of the carcass layer 26 as axis a-a'.

The width of each turn of the carcass layer 26 is advantageously between 25mm and 100 mm.

The carcass layer 26 has, between each pair of stapled turns, a first axial play defined by the relative axial sliding travel of the outer portion 36 of the turn in the inner portion 32 of the adjacent turn to which it is incorporated.

The insert 28 is partially positioned in the gap 40 and closes the gap 40 towards the axis a-a'.

Thus, the insert 28 advantageously has a helical shape of axis a-a', with a pitch P1 that is similar to the pitch of the gap 40.

As shown in FIG. 3, the insert 28 has a relaxed S-shaped cross-section taken in the axial mid-plane.

The insert comprises an axially outer region 42, a radially intermediate region 44 and an axially inner region 46 projecting from the intermediate region 44, axially opposite the axially outer region 42 and radially remote from the axially outer region 42.

The axially inner region 46 at least partially encloses the gap 40. Advantageously, the axially inner region 46 completely closes the gap 40.

According to the invention, the insert 28 is made in a single piece by bending the second strip 48.

The second strip 48 is preferably metal. Advantageously, it has a constant thickness e 2. The thickness e2 of the second strip material 48 is preferably smaller than the thickness e1 of the first strip material 31. The thickness e2 of the second strip material 48 is advantageously between one third and two thirds of the thickness e1 of the first strip material 31.

The thickness e2 is, for example, between 0.5mm and 2mm, in particular between 0.8mm and 1.5 mm.

Such a thickness ensures sufficient rigidity while limiting the risk of disintegration when introducing the probe into the central channel 16 ("pigging" operation).

In the example shown in fig. 2 and 3, the outer region 42 extends over the cylindrical envelope of the central axis a-a'.

The outer region 42 is sandwiched between the outer leg of the U of the outer portion 36 of the turn of the carcass layer 26 and the outer portion leg of the U of the inner portion 32 of the adjacent turn of the carcass layer 26. The outer region 42 is applied against the inner surface of the outer portion 36.

As shown in fig. 3, the intermediate region 44 includes a curved outer segment 50 connected to the outer region 42, an intermediate segment 52 having a linear cross-section, and a curved inner segment 54 connected to the inner region 46.

The outer segment 50 has an outwardly directed convex curvature. The radius of curvature of the outer segment 50 is advantageously greater than the thickness e2 of the second strip material 48.

The intermediate section 52 extends obliquely with respect to an axis perpendicular to the central axis a-a', while being axially distant from the outer and inner sections 42, 46.

The inner subsection 54 has an inwardly directed convex curvature opposite to the convex curvature of the outer subsection 50. With a radius of curvature greater than that of the outer segment 50.

The intermediate region 44 is applied to the inner surface of the intermediate portion 34. Which is complementary in shape to the intermediate portion 34.

The intermediate region 44 is positioned in the gap 40 between the intermediate and outer portions 34, 36 of the turn of the carcass layer 26 and the inner portion 32 of the adjacent turn of the carcass layer 26.

The outer region 42 projects axially from an outer segment 50 of the intermediate region 44.

The inner region 46 also extends axially along the axis a-a 'over the cylindrical envelope of a-a', or at an angle of less than 10 ° relative to the envelope.

Preferably, when the inner region 46 is positioned on the cylindrical envelope of the axis a-a ', the inner region 46 is resiliently urged towards an inclined position relative to the cylindrical envelope of the axis a-a', as shown by the thin lines in fig. 3.

Width L1 of inner region 46 taken along axis a-a 'is greater than width L2 of outer region 42 taken along axis a-a'. In the variant of fig. 11, the insert 28 has an L-shape, the insert 28 not comprising the outer zone 42.

The inner region 46 extends axially opposite the outer region 42 relative to the intermediate region 44 and radially away from the intermediate region.

The inner region protrudes from an inner section 54 of the intermediate region 44.

Referring to fig. 2, the interior region 46 of each turn of the insert 28 includes: a first axial section 56 applied on the inner surface 39 of the inner portion 32 of the turn of the carcass layer 26; an axially intermediate section 58 which internally closes the gap 40 delimited by the inner portion 32; and a second axial segment 60 applied on the inner surface of the inner region 46 of the adjacent turn of the insert 28 at the first axial segment 56 of the inner region 46.

The inner region 46 of each turn of the insert 28 is advantageously held in application against the inner surface of the inner region 46 of one turn of the insert 28 by resiliently urging the inner region 46 outwardly.

Thus, successive turns of the insert 28 overlap one another by their inner regions 46 so as to internally close the gap 40.

The overlap width of each interior region 46 is greater than the axial play of the carcass layer 26 when the carcass layer 26 occupies an undeformed linear configuration.

With reference to fig. 1, the pressure shield 27 is intended to absorb forces related to the pressure prevailing inside the pressure jacket 20. For example, the pressure shield 27 is formed from a helically wound metal profile wire around the sheath 20. Profiled wires usually have complex geometries, in particular a Z-shape, T-shape, U-shape, K-shape, X-shape or I-shape.

The pressure shield 27 is helically wound around the pressure jacket 20 at a short pitch, i.e. the absolute value of the helix angle is close to 90 °, typically between 75 ° and 90 °.

The flexible pipe 10 according to the present invention comprises at least one protective layer 24, 25 formed by helical winding of at least one elongated protective element 63.

In the example shown in fig. 1, the flexible pipe 10 comprises a plurality of protective layers 24, 25, in particular an inner protective layer 24 applied on a pressure shield 27 and an outer protective layer 25 positioned around the outer protective layer 30.

Each armour layer 24, 25 comprises longitudinal armour elements 63 wound at a long pitch around the axis a-a' of the pipe.

By "wound with a long pitch" is meant that the absolute value of the helix angle is less than 60 °, and typically between 25 ° and 55 °.

Generally, the protective elements 63 of the first layer 24 are wound according to an opposite angle with respect to the protective elements 63 of the second layer 25. Thus, if the winding angle of the protective element 63 of the first layer 24 is equal to + α between 25 ° and 55 °, the winding angle of the protective element 63 of the second protective layer 25 positioned in contact with the first protective layer 24 is equal to- α °, for example.

The protective element 63 is formed, for example, by a metal wire, in particular a steel wire, or by a strip of composite material, for example a strip reinforced with carbon fibres.

Outer jacket 30 is intended to prevent fluid from penetrating from the exterior to the interior of flexible pipe 10. The outer sheath is advantageously made of a polymeric material, in particular based on a polyolefin (for example polyethylene) or on a polyamide (for example PA11 or PA 12).

The thickness of the outer sheath 30 is for example between 5mm and 15 mm.

The tubular reinforcement 29 comprising the carcass layer 26 and the insert 28 is manufactured in the machine 100 according to the invention, as shown in figures 4 to 10.

The machine 100 comprises a central mandrel 102 defining an outer tubular surface 104 for supporting and shaping the tubular reinforcement 29. The machine comprises: a rotary support 106 rotatably mounted about a winding axis E-E' of the central mandrel 102; and a forming device 108 carried by the rotary support 106 for co-rotational movement with the rotary support 106.

The forming device 108 includes a forming machine apparatus 110, a first feeder 112 for feeding the flat first strip 31 to the forming apparatus 110 to form the preformed first strip 31, and a second feeder 114 for feeding the flat second strip 48 to the forming machine apparatus 110, and co-forming the second strip 48 with the preformed first strip 31 to form a combined formed strip 196 to be wound on the outer tubular surface 104.

The molding apparatus 108 further includes a locking device 115 that is capable of closing and interlocking successive turns of the combined molding strip 196.

In this example, the central mandrel 102 directly defines an outer surface 104 around which the tubular reinforcement 29 is wound.

In this example, the central mandrel 102 is formed from a metal tube that defines an outer surface 104.

In one variant (not shown), the outer surface 104 is defined onto a tubular sheath of the pipe.

The rotary support 106 is here formed by a circular table. The rotational support 106 defines a front face 116 and a back face 118 opposite the front face 116. The rotational support defines a central through-passage 120 between the front and rear faces 116, 118 through which the spindle 102 extends.

The rotary support 106 is rotatable with respect to the outer surface 104 about the winding axis E-E' so as to allow winding of successive turns of the tubular reinforcement 29 in a helical shape. The tubular reinforcement formed on the outer surface 104 is slidable on the outer surface 104 along the axis E-E'.

As described above, the forming device 108 is carried by the rotating support 106 so as to rotate with the rotating support 106. The former apparatus 110 includes at least one (preferably a plurality) of upstream forming stations 122A-122G, at least an intermediate joining station 124, and at least one (preferably a plurality) of joining forming stations 126A-126C for co-forming the first 31 and second 48 ribbons.

The molding machine apparatus 110 also includes a common support 128 that carries the upstream forming stations 122A-122G, the joining station 124, and the downstream forming stations 126A-126C. The molding machine arrangement comprises a displacement device 129 of the common support body 128 on the rotary support 106.

The upstream forming stations 122A-122G, the joining station 124, and the downstream forming stations 126A-126C each include a pair of opposed rollers 130, 132 defining a forming gap 134 therebetween.

The rollers 130, 132 are rotatably mounted about axes of rotation parallel to each other and to the winding axis E-E'. The rollers 130, 132 each define a row on the common support 128. The interstices 134 between the respective rollers 130, 132 are preferably aligned along a forming axis F-F 'perpendicular to the winding axis E-E'.

The rollers 130, 132 advantageously have an average diameter of between 10cm and 30 cm.

The upstream forming stations 122A to 122G are configured to receive the flat first strip 31 from the first feeder 112 and to form the pre-shaped first strip 31 by deforming at least one region of the flat first strip 31 to form a cross section distinct from that of the flat first strip 31.

The upstream forming stations comprise at least one station 122A, 122B for forming the intermediate portion 34 of the first strip 31, at least one station 122C for forming the support wave 38 and a plurality of stations for pre-bending the edges of the first strip 31 to form the inner portion 32 and the outer portion 36 of the first strip 31.

In fig. 5, a station 122B for forming the intermediate portion 34 of the first strip 31 is shown. In a cross section in a plane P joining the axes of rotation of the rollers 130, 132, the first roller 130 defines at least an inclined step 138 between two flat zones 139 parallel to the axes of rotation.

In this example, the roller comprises two discs 136A, 136B defining a step 138 and a first lateral disc 136C for positioning a first lateral edge of the first strip 31 and for laterally closing the gap 134 on a first side.

In plane P, the second roller 132 also defines a step 142 between two flat zones 143 parallel to the rotation axis. The step 142 is positioned facing the step 138 and spaced apart therefrom. The flat zones 139, 143 face each other and are spaced apart from each other.

In this example, the roller 132 comprises two discs 140A, 140B defining a step 142 and a lateral disc 140C for positioning the second side edge of the first strip 31 and for laterally closing the gap 134 on the second side.

The gap 134, obtained in section in a plane containing the axes of rotation of both rollers 130, 132, comprises first and second flat zones 144, 148 defined between the respective flat zones 139, 143, and an intermediate stepped zone 146 defined between the flat zones 144, 148, between the steps 138, 142.

In another upstream preformation station 122C shown in fig. 6, the rollers 130 define circumferential grooves 150 to form the support waves 38. Here, a groove 150 is made on one side of the disc 136B.

The gap 134 also includes a sloped region 152 on one side of the rollers 130, 132 to initiate bending of the first strip 31 along the first side edge.

The inclined region 152 is defined here between a protruding region of the first roller 130 and a corresponding recessed region of the second roller 132.

Platform 122C does not include lateral disks 136C, 140C.

In another upstream preforming station 122F, the first roller 130 comprises a lateral annular projection 154 for continuing to bend the first lateral edge of the first strip 31. The projections 154 have curved concave surfaces extending along the curved convex lateral surfaces of the second roller 132. Where the tabs 154 are formed on the disk 136A.

The second roller 132 further comprises lateral annular projections 156 for partially deforming the second lateral edge of the first strip 31 comprising the support waves 38. The projections 156 have curved concave surfaces extending along the curved convex lateral surfaces of the first roller 130. The projection 156 is formed on the disk 140B here.

The curved concavity is capable of bending the side of the first strip 31 at an angle greater than 45 °, in particular greater than 80 °, with respect to the flat region 144 of the void 134.

As shown in fig. 8, in the intermediate joining station 124, the first roller 130 is a guide roller configured for redirecting the second strip 48 from the second feeder 114 to the downstream forming stations 126A-126C, the second strip 48 remaining as a flat strip.

The first roller 130 defines, in cross-section in plane P, a flat zone 158 for deflection without deformation of the second strip material 48. The flat zone 158 is advantageously delimited on one side by a positioning tab for abutting against an edge of the flat second strip 48.

The flat band 158 is capable of redirecting the second strip 48 from the second feeder 114 to a direction parallel to the forming axis F-F'. The second ribbon 48 remains flat as it is deflected by the first roller 130. The second strip material has the same cross-section both before and after passing through the first roller 130.

Advantageously, the first roller 130 is mounted so as to be freely rotatable about its axis, without being driven.

In the intermediate joining station 124, the second roller 132 has a similar shape to the second roller of the upstream preformation station 122F, so as to support a preformed first strip 31 facing the flat zone 158 and in contact with the second strip 48 or at a short distance from the second strip 48, for example at a distance less than the thickness of the second strip 48.

Thus, the preformed first 31 and second 48 strips are joined by being placed with the longitudinal local axes parallel to each other. The preformed first 31 and second 48 strips are close to each other, preferably in contact with each other.

The preformed first tape 31 is also in contact with the second roller 132. It is advantageously laid on the second roller 132 so that the second roller 132 prevents the preformed first strip 31 from falling under gravity.

The gap 134 locally has a width, taken perpendicular to the axes of rotation of the rollers 130, 132, which is greater than the sum of the thickness of the first strip and the thickness of the second strip 48.

In the downstream bonding stations 126A, 126B, successive rollers 130, 132 can co-form the first 31 and second 48 strips such that the cross-section of each of the first 31 and second 48 strips changes after passing through the rollers 130, 132.

In the example of fig. 9 and 10, the first roller 130 also includes a step 138 facing and spaced apart from a step 142 defined on the second roller 132. The step 138 enables the second strip 48 to be shaped so as to form an intermediate region 44 having a shape complementary to the shape of the intermediate portion 34 of the first strip 31.

The first roller 130 also defines a lateral curved surface 160 that defines a lateral slot 162 for continuing to bend the outer portion 36 of the first strip 31, including the support wave 38, without collectively bending the second strip 48.

Here, a laterally curved surface 160 is defined on the disc 136B of the first roller 130. A slot 162 is defined between the discs 136A and 136B of the first roller 130.

Similarly, the second roller 132 defines a lateral curved surface 164 for bending the inner portion 32 of the first strip 31 and a groove 166 for receiving the curved portion of the inner portion 32.

The projection 138 is formed here on the first disk 136A. The lateral surface 164 is defined on the lateral disc 140B of the second roller 132. A slot 166 is defined between the first and second disks 140A, 140B of the second roller 132.

The interspace 134 therefore comprises a central zone 168 in which the joint deformation of the first 31 and second strip 48 takes place, in particular in order to form the inclined intermediate portion 34 of the first strip and the intermediate zone 44 of the second strip 48.

Void 134 also includes: two zones 170 delimited by the grooves 162, 166, which are intended to deform only the first strip 31; and a region 172 for maintaining the flat shape of the second ribbon 48 so as to form the inner region 46 of the second ribbon 48.

The first feeder 112 is configured to feed the first strip 31 to the upstream forming station 122A in order to pre-form the first strip 31.

The first feeder comprises a first unwinder 180 around which the first flat strip 31 is wound. The first unwinder 180 is here fixed on the opposite face 118 of the rotary support 106.

The first feeder 112 also comprises first guide rollers 182A, 182B, 182C, which, when entering the upstream forming station 122A, are able to guide the first strip 31 from the unwinder 180 and to twist it so as to be aligned with the forming axis F-F'.

The second feeder 114 includes a second unwinder 184 and second guide rollers 186A, 186B to feed the second strip 48 as a flat strip into the intermediate joining station 124.

The second guide rollers 186A, 186B are configured to change the direction of the local longitudinal axis of the second strip material 48 without changing the cross-section of the second strip material 48 (i.e., maintaining the second strip material 48 as a flat strip material).

In the example of fig. 4, the second feeder 114 also comprises a brake 187 for controlling the feeding speed of the second strip 48 and a pair of registration rollers 188 capable of inserting the flat second strip 48 into the intermediate joining station 124 along a predetermined feeding direction G-G ', which is not parallel to the forming axis B-B ', in particular perpendicular to the forming axis F-F '. The predetermined direction of feed G-G 'forms an angle of between 45 ° and 135 ° (in particular 90 °) with the forming axis F-F',

the support 128 holds, in succession, the successive rollers 130, 132 of each platform 122A to 122G, 124, 126A to 126C along the forming axis F-F'.

The shift device 129 includes: a transverse shifter 130 capable of at least moving the support body 128 and the forming axis F-F 'transversely with respect to the mandrel axis E-E'; and an axial displacer 192 capable of moving the support body 128 along the forming axis F-F'.

A method for manufacturing the tubular reinforcement 29 according to the invention will now be described.

When performing the method, the first feeder 112 is activated to unwind the first flat strip 31 so as to feed it to the upstream forming stations 122A to 122G.

The first tape 31 is guided by the guide rollers 182A, 182B, 182C and is advantageously twisted and aligned so as to be parallel to the forming axis F-F'.

The first web 31 then travels through successive upstream forming stations 122A-122G. The first web is progressively formed in successive gaps 134 between the rollers 130, 132 of successive upstream forming stations 122A to 122G.

As shown in fig. 5, in the stations 122A to 122B, the first strip 31 is first bent in the stepped region 146 so as to form the intermediate portion 34 of the shaped first strip 31, the other portions of said first strip 31 remaining flat.

Then, as shown in FIG. 6, the support wave 38 is formed in the slot 150 of the table 122C. As shown in fig. 7, in the subsequent upstream forming stations 122D to 122F, the edge of the first web 31 is gradually curved.

In fig. 7, the side edges of the first strip 31 are now partially bent to define an inner portion 32 and an outer portion 36 having an open J-shape. Thus, the first web 31 is preformed as it enters the intermediate joining station 124.

Simultaneously, the second feeder 114 is activated to unwind the second strip material 48 from the second unwinder 184. The second ribbon 48 travels along rollers 186A, 186B, 186C to reach brake 187 and registration rollers 188. Said second strip is then aligned along a feeding direction G-G 'at a predetermined angle to a forming axis F-F'. The second strip is still a flat strip.

In the joining station 124, the second strip 48 is fed as a flat strip and is aligned so as to be parallel to the forming axis F-F' by contact with the flat band 158 of the first roller 130.

The preformed first strip 31 is supported only on the second roller 132 to be placed facing the second strip 48.

Thus, the longitudinal local axes of the preformed first strip 31 and the flat second strip 48 are placed parallel to each other. The preformed first strip 31 and the flat second strip 48 are adjacent to each other, preferably in contact with each other.

Then, in the downstream forming stations 126A to 126C, the first 31 and second 48 strips are co-formed in the central region 168 of the gap 134 between the rollers 130, 132. The sections of the intermediate region 44 of the second strip 48 and the intermediate portion 34 of the first strip 31 and of the axially outer region 36 of the first strip and the outer portion 36 of the first strip 31 are shaped with complementary shapes in contact with each other.

Furthermore, in the region 170 of the gap 134, in particular in the grooves 162, 166, the edge of the first strip 31 is deformed without deformation of the second strip 48 to form an open U-shape.

Finally, in region 172, second ribbon 48 remains flat to form flat inner region 46 of insert 28.

The combined formed rod 196 obtained at the outlet of the former apparatus 110 is then fed to the outer surface 104 of the mandrel 102. As the mandrel 102 is driven in translation along the axis E-E ', the rotary support 106 continues to rotate about the axis E-E'.

The combined shaped strip 196 is then spirally wound around surface 104 to form successive turns having a desired pitch.

At the same time, the partially open outer portion 36 of each turn of the first strip 31 is inserted into the inner portion 32 of the adjacent turn, the outer region of the insert 28 being inserted between the outer portion 36 of said turn and the inner portion of said adjacent turn.

The inner region 46 of each turn of the second strip material 48 is applied over the inner region 46 of the adjacent turn so as to close the gap 40 formed between successive turns of the first strip material 31.

The radial application members of the locking device 115 are then applied on the outside of the combined profile strips 196 in order to close and interlock the carcass layer 26 and the insert 28.

Once the tubular reinforcement 29 has been manufactured, the inner sheath 20 is formed around the carcass layer 26, for example by extrusion. The pressure shield 27 and the protective layers 24, 25 are then wound around the inner sheath 20. The outer jacket 30 is then advantageously formed by extrusion and is positioned simultaneously on the outside of the protective layers 24, 25.

The method of manufacturing the tubular reinforcement 29 is easy to operate by means of the machine 100 according to the invention. The co-deformation of the first 31 and second 48 tapes ensures a perfect fit between the tapes 31, 48 before the carcass layer 26 is interlocked. Furthermore, the feeding of the second strip 48 as a flat strip in the joining station 124 is easy to operate and does not require cumbersome arrangements.

The first feeder 112 for the first strip 31, the second feeder 114 for the second strip 48 and the molding machine apparatus 110 are all fitted on the same rotating support 106, which simplifies the equipment required to form the carcass layer 26 and reduces its bulk. Thus, the machine 100 is particularly suited for forming a carcass layer.

The second strip 48 is easily introduced into the machine 100 by using a simple deflection roller 130 of the joining station 124. Thus, the machine for forming only the first strip 31 can be easily retrofitted to include the joining station 124 for the second strip 48.

In a variant, the tubular reinforcement 29 is formed on an outer surface 104 defined on an inner sheath of the conduit.