Automated pipe shops and software for pipe spool fabrication
3R solutions GmbH
Hamm (headquarters)New on Amplifa
About 3R solutions
3R solutions GmbH, headquartered in Hamm (Germany), specializes in the automation of pipe shops for pipe spool fabrication. Originally founded in 1982 as a software company for customized automation solutions – its first customers were German shipyards – the company today offers turnkey pipe shops that combine automated transport systems, pipe processing machines (pipe bending machines including double-head and multi-axis freeform bending machines, automatic flange welding machines, TIG/MAG welding systems, pipe dispensers, spool positioners) with an integrated shop floor control software. The software transfers CNC data to the machines, calculates the optimal machining sequence, tracks the status of all pipes in production and includes its own software framework that is also usable as a standalone solution – such as the Kolli bending simulation with automatic collision detection, the Freeform Manager for variable radius bending, IsoBuilder (RoniCAD), the process tracking tool RonPro and JointCheck Web for weld seam management. Materials used in the projects are stainless steel and steel pipes. Industries served are mainly shipbuilding and shipyards, offshore/oil platform construction, chemical plants, hydrogen electrolysers, seawater desalination, steel construction, coking plant technology and the automotive industry. With more than 40 completed projects worldwide, the company operates internationally.
- Site
- Hamm
- Processes
- Pipe spool fabrication, Pipe bending (tube bending, incl. freeform bending with variable radius), Flange welding (automatic slip-on flange welding machine), TIG/MAG welding (automated), Pipe transport and handling (automated transport system, pipe storage, pipe dispenser), Bending simulation with automatic collision detection (bend validation), Pipe shop automation (turnkey pipe shops), Automated transport systems
- Materials
- Stainless steel (pipes), Steel (pipes), Stainless steel pipes, Steel pipes, Pipe bending (tube bending, incl. double-head and multi-axis freeform bending, Welding (automated flange/TIG/MAG welding systems), Automatable logistics in the shop, Spool positioner
- Certificates
- ISO 9001, ISO 9001 (logo on website)
- Founded
- 1982
- Industries
- Shipbuilding/shipyards, Offshore/oil platform construction, Chemical plants, Hydrogen electrolysers, Seawater desalination, Steel construction
- 01
Requirements analysis and consulting
- 02
Concept. plant layout design of the pipe shop
- 03
Hardware procurement
- 04
Software development / shop floor control (CNC data transfer)
- 05
Installation coordination
- 06
Commissioning
- 07
Support and process tracking (RonPro, JointCheck Web)
Materials and processes
Stainless steel pipes
Pipe spools made of stainless steel, among others in the stainless steel pipe shop for KeppelFELS in Singapore (StainlessShop, phases 2014/2015).
Steel pipes
Steel pipes for the fabrication of components in the automated pipe shops.
Pipe bending (tube bending, incl. double-head and multi-axis freeform bending
Bending of pipes including variable radius (Freeform Manager) with automatic collision detection (Kolli) beforehand.
Welding (automated flange/TIG/MAG welding systems)
Automatic slip-on flange welding machine and TIG/MAG systems, among others for projects in Singapore (2013/2014).
Automatable logistics in the shop
Automated transport systems, pipe storage and pipe dispensers for in-house handling and material flow.
Spool positioner
In-house development (2015) for positioning pipe spools in production.
Locations
Hamm
DEHeadquarters
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Pipe spool fabricationJoining | – | – | – | – | Stainless steel (pipes), Steel pipes |
| Pipe bending (tube bending, incl. freeform bending with variable radius)Forming | – | – | – | – | – |
| Flange welding (automatic slip-on flange welding machine)Joining | – | – | – | – | Stainless steel, Steel |
| TIG/MAG welding (automated)Joining | – | – | – | – | Stainless steel, Steel |
| Pipe transport and handling (automated transport system, pipe storage, pipe dispenser)Assembly | – | – | – | – | – |
| Bending simulation with automatic collision detection (bend validation)Engineering | – | – | – | – | – |
6 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Pipe bending machine (incl. double-head bending machines with multiple tools) | – | – | – | – | various customer shops |
| Automatic flange welding machine | – | – | – | – | Singapore |
| TIG/MAG automated welding machine | – | – | – | – | Singapore |
| Spool positioner | 3R | – | – | 2015 | – |
| Pipe dispenser | – | – | – | – | Singapore |
| Automated transport system for pipe shops | 3R (turnkey solution) | – | – | – | – |
Additional services
Reference customers
Quality
According to website evidence, 3R solutions operates in accordance with ISO 9001; the JointCheck Web software supports quality documentation and management of weld seams in piping construction.
| Evidence | Hamm |
|---|---|
| ISO 9001 (logo on website) |
History
- 1982
Foundation; began as a software company for customized automation solutions for pipe shops, first customers German shipyards
- 1985
Development of bending collision check software
- 1995
Redevelopment of the RONI software for Windows NT
- 2002
Development of three customized shop floor controls
- 2005
Simulation of double-head bending machines with multiple tools
- 2007
Development of the process tracking tool RonPro; new version of the Kolli bending software
- 2009
Consulting for a pipe shop project in Singapore; re-design of RoniCAD as IsoBuilder; pipe bending solution for Evobus/Daimler; coking plant monitoring software
- 2010
Pipe shop project in Singapore
- 2011
Commissioning of a fully automated pipe shop in Singapore; development of the Freeform Manager
- 2013
Largest pipe shop project (VARD/STX OSV Romania); automatic flange welding machine; 3R framework at P+S shipyards (Stralsund)
- 2014
Start of stainless steel pipe shop for KeppelFELS (Singapore); delivery of TIG/MAG welding machine
- 2016
Largest shop project since founding (Dubai); development of JointCheck Web
- 2017
Cooperation agreement for the Korean market; two pipe shops in the UAE
- 2019
Start of major projects in China and Singapore; software project for a large German shipyard
- 2021
Major order for a turnkey shop project in Saudi Arabia; turnkey project UAE completed
- 2023
Turnkey shop projects in China and Singapore completed; pipe shop solution in Germany
- 2024
Further project in Saudi Arabia; consulting for Mexico, France, USA
- 2025
Completion of a turnkey shop project in Saudi Arabia