Control system and method for building tapered structures

Abstract

A control system for forming a tapered structure includes a sensor that provides feedback to a machine for forming a tapered structure, the machine including at least three rollers, the rollers having at least one curved roller and at least two guide rollers. The guide rollers may include a roller row having a plurality of rollers. The machine may also include an adjustment mechanism to position at least one roller, wherein the diameter of the tapered structure being formed is controlled by the relative position of the rollers. The machine may also include a connecting element to connect the edges of the material blank together as it rolls over the rollers to form the tapered structure. The control system may also include a controller to receive feedback from the sensor and send a control signal based on the feedback to the adjustment mechanism to position at least one roller.

Description

[0001] This application is a divisional application of the international application PCT / US2015 / 022648 (national application number No. 201580028200.0, invention name “Control system and method for constructing a tapered structure”, international application date March 26, 2015, priority date March 28, 2014), which entered the Chinese national phase on November 28, 2016.

[0002] Cross-application of related applications

[0003] This application claims priority to U.S. Patent Application No. 14 / 228,481, filed on March 28, 2014, which is incorporated herein by reference in its entirety.

[0004] This application is related to U.S. Patent Application No. 13 / 623,817 filed on September 20, 2012, which claims priority to U.S. Provisional Application No. 61 / 537 filed on September 20, 2011, each of which is incorporated herein by reference in its entirety.

[0005] This application is also related to U.S. Patent Application No. 12 / 693,369, filed January 25, 2010, which is incorporated herein by reference in its entirety.

[0006] STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT

[0007] This invention was made with Government support under Contract DE-SC0006380 awarded by the Department of Energy. The Government has certain rights in this invention.

[0008] This invention was made with government support under NSF SBIR PI under Grant 1248182 from the National Science Foundation. The government has certain rights in this invention. Technical Field

[0009] The present invention generally relates to a control system for building a tapered structure, and a method for controlling a machine for building a tapered structure. Background Art

[0010] There are a variety of techniques and apparatuses that can produce tapered structures, such as conical or truncated conical structures. One general method of building a tapered structure involves bending or deforming a metal stock in a desired manner and then joining the stock to itself at certain points, or joining the stock to other structures at certain points. Control systems for such techniques do not facilitate substantially continuous and precise construction of tapered structures, such as for use as wind turbine towers.

[0011] There are spiral welding machines that form continuous diameter tubes (e.g., pipes, etc.). These machines may include a control system in which an operator adjusts parameters of the spiral welding machine based on measurements of the tube diameter. However, making a tapered structure has additional degrees of freedom that are difficult to control, and therefore a control system and method for building a tapered structure is needed in which a machine for forming a tapered structure is continuously and automatically adjusted to produce a tapered structure that is substantially error-free. Summary of the invention

[0012] In general, on the one hand, a control system for forming a tapered structure includes a sensor that provides feedback to a machine for forming the tapered structure. The machine for forming the tapered structure may include at least three rolls, the rolls including at least one bending roll and at least two guide rolls. The guide rolls may include a roller (rollette) row, the roller row having a plurality of rollers. The machine for forming the tapered structure may also include an adjustment mechanism, the adjustment mechanism is configured to position at least one roll, wherein the diameter of the tapered structure being formed is controlled by the relative position of the rolls. The machine for forming the tapered structure may also include a connecting element, the connecting element is configured to connect the edges of the material blank together when the material blank rolls over the rolls to form the tapered structure. The control system may also include a controller, the controller is configured to receive feedback from the sensor, and send a control signal based on the feedback to the adjustment mechanism to position at least one roll.

[0013] In general, on the other hand, a control system for forming a tapered structure includes a sensor that provides feedback to a machine for forming a tapered structure. The machine for forming a tapered structure may include at least three rollers, the rollers including at least one bending roller and at least two guide rollers. The guide rollers may include a roller row, the roller row having a plurality of rollers. The machine for forming a tapered structure may also include a feed adjustment mechanism, the feed adjustment mechanism is configured to position the material blank when the material blank is fed into the rollers, wherein the material blank forms the tapered structure when rolling over the rollers. The machine for forming a tapered structure may also include a connecting element, the connecting element is configured to connect the edges of the material blank together when the material blank rolls over the rollers to form the tapered structure. The control system may also include a controller, the controller is configured to receive feedback from the sensor, and send a control signal based on the feedback to the feed adjustment mechanism to position the material blank when the material blank is fed into or fed through the machine for forming the tapered structure.

[0014] In general, in yet another aspect, a control system for forming a tapered structure includes an edge position sensor configured to provide feedback including the position of an edge of a material blank to be formed into the tapered structure in a machine for forming the tapered structure. The machine for forming the tapered structure may include: a rolling assembly having a plurality of rollers; a linking element configured to link the edges of the material blank together as the material blank rolls through the rolling assembly to form the tapered structure; an outward movement system configured to support the tapered structure after the edges are linked; and an adjustment mechanism configured to position the tapered structure relative to the rolling assembly. The control system may also include a controller configured to receive feedback from the edge position sensor and to send a control signal based on the feedback to the adjustment mechanism to achieve a desired relative movement between portions of the tapered structure.

[0015] In general, on the other hand, a control system for forming a tapered structure includes a model used in a machine for forming a tapered structure. The machine for forming the tapered structure may include at least three rollers, the rollers including at least one bending roller and at least two guide rollers. The guide rollers may include a roller row, the roller row having a plurality of rollers. The machine for forming the tapered structure may also include an adjustment mechanism, the adjustment mechanism is configured to position at least one roller, wherein the diameter of the tapered structure being formed is controlled by the relative position of the rollers. The machine for forming the tapered structure may further include a connecting element, the connecting element is configured to connect the edges of the material blank together when the material blank rolls over the rollers to form the tapered structure. The model may include the relative positions of the rollers for achieving the desired tapered structure diameter. The control system may also include a computer configured to implement the model, and a controller, the controller is configured to receive instructions based on the model, and send control signals based on the instructions to the adjustment mechanism to position at least one roller.

[0016] In general, in another aspect, a control system for forming a tapered structure includes a model used in a machine for forming a tapered structure. The machine for forming a tapered structure may include at least three rollers, the rollers including at least one curved roller and at least two guide rollers. The guide rollers may include a roller row, the roller row having a plurality of rollers. The machine for forming a tapered structure may also include a feed adjustment mechanism, the feed adjustment mechanism is configured to position the material blank when the material blank is fed into the rollers, wherein the material blank forms the tapered structure when rolling over the rollers. The machine for forming a tapered structure may further include a connecting element, the connecting element is configured to connect the edges of the material blank together when the material blank rolls over the rollers to form the tapered structure. The model may include relative positions of the material blank when it is fed into the machine for forming a tapered structure or fed through the machine for forming a tapered structure. The control system may also include a computer configured to implement the model, and a controller configured to receive instructions based on the model, and send control signals based on the instructions to the feed adjustment mechanism to position the material blank.

[0017] In general, on the other hand, a method for controlling the formation of a tapered structure includes sensing at least one of the following with a sensor on a system for forming a tapered structure: a geometric property of the tapered structure being formed and a force property of the tapered structure being formed. The system for forming the tapered structure may include at least three rollers, the rollers including at least one bending roller and at least two guide rollers. The guide rollers may include a roller row, the roller row having a plurality of rollers. The system for forming the tapered structure may also include an adjustment mechanism, the adjustment mechanism configured to position at least one roller, wherein the diameter of the tapered structure being formed is controlled by the relative position of the rollers. The system for forming the tapered structure may further include a connecting element, the connecting element configured to connect the edges of the material blank together when the material blank rolls over the rollers to form the tapered structure. The method may also include: sending feedback from the sensor to the controller, wherein the feedback is based on at least one of the geometric property and the force property; sending an adjustment instruction from the controller to the adjustment mechanism, wherein the adjustment instruction is based on the feedback; and adjusting the position of at least one roller based on the adjustment instruction by the adjustment mechanism.

[0018] In general, on the other hand, a method for controlling the formation of a tapered structure includes sensing the position of a material blank used to form a tapered structure using a sensor on a system for forming a tapered structure. The system for forming a tapered structure may include at least three rollers, the rollers including at least one bending roller and at least two guide rollers. The guide rollers may include a roller row having a plurality of rollers. The system for forming a tapered structure may also include a feed adjustment mechanism, the feed adjustment mechanism being configured to position the material blank when the material blank is fed into at least one roller, wherein the material blank forms a tapered structure when rolling over the rollers. The system for forming a tapered structure may further include a connecting element, the connecting element being configured to connect the edges of the material blank together when the material blank rolls over the rollers to form a tapered structure. The method may also include: sending feedback from a sensor to a controller, wherein the feedback is based on the position of the material blank; sending adjustment instructions from the controller to a feed adjustment mechanism, wherein the adjustment instructions are based on the feedback; and using the adjustment mechanism to adjust the position of the material blank when it is fed into or fed through a system for forming a tapered structure based on the adjustment instructions.

[0019] In general, on the other hand, a method for controlling the formation of a tapered structure includes sensing the position of an edge of a material blank to be formed into a tapered structure using an edge position sensor on a system for forming a tapered structure. The system for forming a tapered structure includes: a rolling assembly having a plurality of rollers; a connecting element configured to connect the edges of the material blank together as the material blank rolls through the rolling assembly to form the tapered structure; an outward displacement system configured to support the tapered structure after the edges are connected; and an adjustment mechanism configured to position the tapered structure relative to the rolling assembly. The method may also include: sending feedback from the edge position sensor to a controller, wherein the feedback is based on the position of the edge of the material blank; sending an adjustment instruction from the controller to the adjustment mechanism, wherein the adjustment instruction is based on the feedback; and using the adjustment mechanism to adjust the position of the tapered structure relative to the rolling assembly based on the adjustment instruction.

[0020] In general, in another aspect, a method for controlling the formation of a tapered structure includes: driving a material blank with a feed system; feeding the material blank through a rolling assembly having at least three rollers, the rollers including at least one bending roller and at least two guide rollers, the guide rollers including a roller row, the roller row having a plurality of rollers; joining the edges of the material blank together to form the tapered structure as the material blank rolls through the rolling assembly; guiding the material blank out of the rolling assembly with an outward movement system; and sensing sensor data including at least one of the following with a sensor: (i) geometric properties of the tapered structure being formed, (ii) force properties of the tapered structure being formed, (iii) position of the material blank, (iv) inconsistencies in a weld gap in the material blank, (v) planar alignment errors in the material blank, and (vi) angular alignment errors in the material blank. The method may also include: sending feedback from the sensor to a controller, wherein the feedback is based on the sensor data; sending adjustment instructions from the controller to an adjustment mechanism, wherein the adjustment instructions are based on the feedback; and using the adjustment mechanism to adjust the position of the material blank based on the adjustment instructions.

[0021] Other implementations of any of the aforementioned aspects may be represented in a variety of forms, including methods, systems, devices, apparatus, computer program products, products produced by processes, or other forms. Other advantages will be apparent from the following drawings and descriptions. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The foregoing and other objects, features and advantages of the systems and methods described herein will be apparent from the following description of specific embodiments of the invention as illustrated in the accompanying drawings, which are not necessarily drawn to scale, emphasis instead being placed upon illustrating the principles of the systems and methods described herein.

[0023] Figure 1 is a block diagram of a construction system for forming a tapered structure.

[0024] Figure 2 It is a schematic diagram of triple rollers.

[0025] Figure 3 It is a three-dimensional diagram of the roller row.

[0026] Figure 4A and 4B It is a top view of the roller row.

[0027] Figure 5A is a perspective view of a construction system for forming a tapered structure.

[0028] Figure 5B is a top view of a building system for forming a tapered structure.

[0029] Figure 6 It is a three-dimensional diagram of the bending device.

[0030] Figure 7 is a plot showing the relationship between the position of the roller row and the resulting radius of curvature of the tapered structure being formed.

[0031] Figure 8 It is a schematic diagram of triple rollers.

[0032] Fig. 9 It is a top view of a structure with a clearance error and a structure without a clearance error.

[0033] Fig.10 is a top view of the structure formed by feeding the material at different angles.

[0034] Fig.11A and 11B It is a schematic diagram of sheet turning.

[0035] Fig. 12A and 12B is a schematic diagram of the in-plane gap error.

[0036] Fig.13A and 13B is a schematic diagram of the out-of-plane gap error.

[0037] Fig.14A and 14B is a schematic diagram of tangency alignment error.

[0038] Fig.15 A close-up view of the subsystems within the machine.

[0039] Fig.16 A close-up view of the off-board subsystems.

[0040] Fig.17 is a flow chart of a method for adjusting weld gap.

[0041] Fig.18 It is the block diagram of the control system.

[0042] Fig.19 is a flow chart of a method for controlling the formation of a tapered structure.

[0043] Fig. 20 is a flow chart of a method for controlling the formation of a tapered structure.

[0044] Fig.21 is a flow chart of a method for controlling the formation of a tapered structure.

[0045] Fig. 22 is a flow chart of a method for forming a tapered structure.

[0046] Fig.23It is a schematic diagram of a solid roller and a roller row.

[0047] Like reference numerals denote like structures. DETAILED DESCRIPTION

[0048] Embodiments will now be described more fully below with reference to the accompanying drawings, in which preferred embodiments are shown. However, the systems and methods described herein may be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein. Rather, these illustrated embodiments are provided so that the disclosure will convey the scope to those skilled in the art.

[0049] All documents provided herein are incorporated herein by reference in their entirety. Items cited in the singular shall be understood to include the plural item, and vice versa, unless otherwise expressly stated or clear from the context. Grammatical conjunctions are intended to express any and all transitional and connecting combinations of clauses, sentences, words, etc., unless otherwise expressly stated or clear from the context. Thus, the term "or" shall generally be understood to mean "and / or" and the like.

[0050] The description of the range of values ​​herein is not intended to be restrictive, but is individually referenced to any and all values ​​falling within the range, unless otherwise provided herein, and each individual value within such a range is incorporated into the specification as if individually described herein. The words "substantially", "approximately", etc. are to be understood as indicating deviations that work satisfactorily for the intended purpose when accompanied by numerical values, as will be understood by those of ordinary skill in the art. The range of values ​​and / or numerical values ​​provided herein is only as an example, without limiting the scope of the described embodiments. The use of any and all examples or exemplary language ("for example", "such as", etc.) provided herein is intended only to better illustrate the embodiments, rather than to impose limitations on the scope of the embodiments. The language in the specification should not be understood to represent any undeclared elements that are essential for practicing the embodiments.

[0051] In the following description, it is to be understood that words such as "top", "bottom", "above", "below", "first", "second", "up", "down", "left", "right", etc. are for convenience and are not intended to be understood as limiting terms.

[0052] It is often desirable to form a tapered structure, such as a cone or truncated cone structure, from a substantially flat blank without introducing significant in-plane deformation to the blank. For example, U.S. Patent Application No. 12 / 693,369, entitled "TAPERD SPIRAL WELDED STRUCTURE," discusses some applications of such structures. In addition, U.S. Patent Application No. 13 / 623,817, entitled "TAPERED STRUCTURE CONSTRUCTION," discusses some construction systems for such structures. Among them, the techniques described below may be used in conjunction with the systems, devices, and methods described in these applications, which are incorporated herein by reference in their entirety. In addition, the control systems and methods described herein may be used in addition to, or in conjunction with, any controllers described in these applications, or in place of any controllers described in these applications.

[0053] Figure 1 1 is a block diagram of a construction system. System 100 includes a blank material source 102 (which may be metal), a feed system 104, a bending device 106, a connecting element 108, an outward movement system 110, and a control system 112. As described more fully herein, system 100 can operate to build a tapered structure. On the one hand, control system 112 controls at least one of the following: blank material source 102, feed system 104, bending device 106, connecting element 108, and outward movement system 110. However, those skilled in the art will appreciate that in other aspects, control system 112 can control more or less components of construction system 100, as well as any combination thereof. In addition, components or combinations thereof may include separate controllers / control systems, wherein, on the one hand, control systems communicate with each other.

[0054] The blank material source 102 may include the original metal that forms the tapered structure. In some embodiments, the blank material source 102 may include a series of flat metal sheets, blank material rolls, etc. that are arranged in any manner described in U.S. Patent Application No. 12 / 693,369 in size. The sheets can be constructed and arranged to facilitate easy selection of desired sheets during the manufacturing process. For example, the sheets can be stored in a hopper or other appropriate distributor. As used in the present disclosure, "blanks", "material blanks", "sheets", etc. should represent materials to be formed into tapered structures, unless otherwise clearly stated herein, or clear from the context. As discussed above, in some embodiments, the blanks may include rolled metal or other materials. In some embodiments, the blanks include separate pre-cut sheets.

[0055] The feed system 104 can operate to transport metal from the blank material source 102 to (and in some embodiments, through) the bending device 106. The feed system 104 may include any such equipment suitable for transporting the desired sheet material according to conventional techniques. Such equipment may include, for example, a robotic arm, a piston, a servo, a screw, an actuator, a roller, a drive, an electromagnet, etc., or any combination of the foregoing. As described herein, the control system may include a feed control system that includes a controller for feeding the blank material into the bending device 106 so that the desired tapered structure can be formed.

[0056] The bending device 106 can operate to bend the material fed thereto, and in one aspect, without applying any in-plane deformation to the material. In addition, the bending device 106 can apply a controllable degree of curvature to the material. In an embodiment, the bending device includes a plurality of rollers. The rollers described herein may include, but are not limited to, rollers (including substantially cylindrical rollers, substantially conical rollers, irregularly shaped rollers, spherical rollers, etc.), roller rows including a plurality of rollers that collectively approximate the exterior of a corresponding solid structure (e.g., smaller rollers, wheels, bearings, spherical rollers, etc.), or any other element that can be used to bend / roll / manipulate the material blank into a tapered structure. The bending device 106 may include Figure 2 Schematically shown in FIG. 2 is a triple roller 200 (described in more detail below). As used in this disclosure, "bending device," "rolling assembly," "triple roller," and the like shall mean any device or member operable to bend material fed thereto (e.g., as described herein), unless otherwise stated or clear from the context.

[0057] The connecting element 108 can be operated to connect the blank of the feed of sheet material to the blank of other feed of sheet material (or to themselves, or to other structures). In some embodiments, the connecting element 108 is a welding machine, which includes one or more welding heads, and the position and operation of the welding head can be controlled by a control system. Generally, the connecting element 108 may include any member or machine for connecting the blank by any known means, including welding, adhesive, epoxy resin, crimping, rivet, bolt, fastener, complementary geometric structure (for example, pins matching with holes, teeth matching each other, push buttons, etc.) and the like. The connecting element 108 can be configured to connect the edges of the material blank together when the material blank rolls over the bending device 106. In some embodiments, there may be a plurality of connecting elements and / or a plurality of steps for connecting the edges of the material blank together. For example, for a trapezoidal sheet blank having a pair of long sides and a pair of short sides, the short sides may be joined first (eg, with other sheet blanks), the blank may then be deformed, and the long sides may then be joined.

[0058] The outward movement system 110 can be operated to transport the material (i.e., the structure being formed or formed) away from the bending device 106 and the connecting element 108. This may include supporting, holding, transporting, moving, guiding, manipulating, pushing, pulling, twisting, etc. the structure being formed. The outward movement system 110 may include any such suitable equipment according to conventional technology. Such equipment may include, for example, a robot arm, a piston, a servo, a screw, an actuator, a roller, a drive, an electromagnet, a subsystem, etc., or any combination of the foregoing. As described herein, the control system may include an outward movement control system, which includes a controller for supporting and positioning the tapered structure being formed after the edges of the material blank are connected.

[0059] The control system 112 may operate to control and coordinate various tasks described herein, including, but not limited to, operating the feed system 104, operating the bending device 106, operating the coupling element 108, and operating the outward movement system 110. The control system 112 may include computer hardware, software, circuitry, etc. that may collectively generate and transmit control signals to the components and systems described herein to achieve the desired tasks.

[0060] The control systems and methods described herein may generally be used with any construction machine described herein, including machines and systems described in the references, which are incorporated herein by reference in their entirety. In general, a "control system" may refer to a separate control system for a separate component / part of a machine, or to a combination of control systems, or to a control system that controls many components / parts of a machine and / or system.

[0061] As discussed herein, it may be desirable to arrange the blanks fed into the system 100 to undergo pure rotational motion during the feeding process. In particular, pure rotational motion may be performed when the blanks are fed into the bending device 106. The control system and method described herein may be designed to achieve this functionality.

[0062] Although the phrase "pure rotational" movement has been used, slight deviations from pure rotation (i.e., slight translations of the blank or the peak relative to each other) may be tolerated. If the blank undergoes any translational movement relative to the peak during the feeding process, the resulting structure may deviate from the ideal truncated cone geometry. In particular, there may be gaps where the blank fails to meet the corresponding edge of the precursor portion of the blank, the blank itself may overlap, or both. Therefore, the control system described herein may control the material blank to prevent translational movement relative to the peak. However, slight translational movement is acceptable, for example, if the gap is kept within a desired range.

[0063] As used in this document, a "substantially rotational" motion means the purely rotational motion described above, except that minor deviations are allowed, which may be useful in later manufacturing processes, or are acceptable because the structure geometry can still be maintained within the desired range / tolerances, or are small enough not to adversely affect the cone geometry, warpage strength, fatigue strength, etc. The extent of these allowed deviations will generally vary with the size of the desired truncated cone structure and the manufacturing steps to accommodate the deviations. Also as used in this document, "rotational motion" should be understood to mean a substantially rotational motion or a purely rotational motion.

[0064] The triple roll will now be described.

[0065] Figure 2 A simplified schematic diagram showing how a basic triple roller 200 may operate. The triple roller 200 may include three substantially cylindrical rollers 204 that are substantially parallel to one another and are operable to impart curvature to a material blank 202 that is fed through the rollers 204 in the direction of dashed arrows 206. The triple roller may also or instead include one or more rows of rollers that are operable to impart curvature to the material blank in the same manner as the solid rollers 204. The degree of curvature may be controlled by, for example, dynamically adjusting the relative positions of the rollers 204 or rows of rollers, etc.

[0066] Figure 3 , 4A 4B show an example of a roller row having a roller steering mechanism including a cam plate steering mechanism. In particular, Figure 3 An example of a roller row 300 is shown. Figure 3 , the roller row 300 may include a plurality of rollers 302. The rollers 302 may include rollers whose axes of rotation may be adjusted relative to other axes of rotation in the triple roll. The rollers 302 may be steered using a cam plate steering system described below. The rollers 302 may include rollers 304 (e.g., cylindrical rollers, spherical rollers, sliding pads, etc.) and a body 306 or housing that may support / hold the rollers 304. The roller row 300 may also include a base 308, wherein the body 306 may dock with the base 308, thereby coupling the rollers 302 to the roller row 300, for example, in a manner that allows rotation relative to the base 308 of the roller row 300. One of ordinary skill in the art will recognize that there are other means of coupling the rollers 302 to the roller row 300.

[0067] The roller row 300 may also include a roller steering mechanism. The roller 302 may dock with the roller steering mechanism, wherein the body 306 or base 308 of the roller row 300 may enable such docking. The steering mechanism may include (without limitation) a cam, a four-bar linkage or other linkage mechanism, a separate steering actuator, etc. For example, Figure 3 A roller steering mechanism is shown that includes a steering actuator 310 that drives a steering cam plate 312 that in turn can steer rollers 302. The roller steering mechanism can also include or instead include any form of roller adjustment mechanism that is configured to position the angle of rollers 302 on roller row 300.

[0068] Figure 4A and 4B A roller row 400 is shown having a roller steering mechanism. The roller row 400 includes a roller 402 having a roller 404 and a roller housing 406. Figure 4A -B also includes a base 408. Figure 4B 4, the roller steering mechanism may include a cam plate actuator 410 configured to move a cam plate 412 at least in the direction shown by arrow 414. The roller 402 may be engaged with the cam plate 412 by any means known in the art, including, without limitation, by a roller arm 416, which includes a cam mating pin 418 connected to the cam plate 412 by a corresponding cam slot 420. The cam mating pin 418 may instead be replaced by a roller, a cam follower, or the like. The cam slot 420 may be cut into a configuration such that when the cam plate 412 moves, the geometry of the cam slot 420 moves the cam mating pin 418, thereby rotating the roller 402. The cam slots 420 in the cam plate 412 may all be identical, or they may be different for each roller 402. If the rollers 402 are identical to one another, and the cam slots 420 on the cam plate 412 are identical, the rollers 402 will move together and will be at substantially the same angle. If the rollers 402 are different from one another (i.e., if the angle of the roller arm 416 relative to the roller axis varies between the rollers 402) and the cam slots 420 in the cam plate 412 are identical, the rollers 402 will move together, but may be at different angles from one another. If the cam slots 420 in the cam plate 412 are different for one or more of the rollers 402, the movement of the rollers 402 will have some correspondence (i.e., with the geometric configuration of the cam slots 420), but they will not necessarily move together. For example, the cam may be constructed so that some rollers do not move at all, while other rollers rotate. One skilled in the art will recognize that many configurations are possible.

[0069] The cam plate 412 itself can be actuated relative to the roller 402 so as to rotate the roller 402. The cam plate 412 can be guided or held in place by any known means, including (without limitation) a cam plate hold-down 422 and a cam plate guide 424, or a slide, bearing, roller, pin, linkage, etc. Activating the cam plate actuator 410 can cause the cam plate 412 to move in the direction shown by arrow 414, which in turn, due to the coupling of the roller arm 416 and the cam plate 412, causes the roller 402 to rotate, for example, along the axis of rotation 426 indicated in FIG. 4. The cam plate 412 can be actuated by any means known to those skilled in the art, including (without limitation) an electric motor, pneumatics, hydraulics, etc.

[0070] A control system and its machine components for rolling a material blank and forming a tapered shape with a substantially continuously changing diameter will now be discussed. As used in the present disclosure, a structure with a "substantially continuously" changing diameter should generally represent a tapered structure, such as a cone, a flat-topped cone, and the like. Similarly, as used in the present disclosure, "substantially continuously" adjusting the diameter (or the like) should generally represent the production of a tapered structure, such as a cone, a flat-topped cone, and the like. As will be appreciated by those skilled in the art, a tapered structure may include an actual peak or a virtual peak. An actual peak is a point where the diameter is ultimately reduced to zero. For example, a cone has an actual peak at its apex. For a flat-top structure, such as a truncated cone structure, a "virtual peak" is a point where the diameter will ultimately be reduced to zero when the structure is not flat-topped. As used herein, the term "peak" includes both an actual peak and a virtual peak.

[0071] exist Figure 5A-6 Embodiments of a machine for forming a tapered structure are shown in FIG. 1 and will now be described in more detail.

[0072] Figure 5A and 5B Depicts a construction system 500 for forming a tapered structure according to an embodiment, wherein Figure 5A A perspective view of the display system 500 is shown, and Figure 5B A top view of the display system 500 is shown. In particular, Figure 5A -B shows a construction system 500 for forming a tapered structure (such as a flat-topped cone 502 that can be used as a wind turbine tower) from a material blank 501. As used in this disclosure, "tapered structure", "cone", "flat-topped cone", etc. shall refer to a structure formed by the devices, systems and methods described herein. System 500 may include multiple subsystems, including a blank material source (not shown), a feed system 504, a bending device 506, a connecting element (not shown), a control system (not shown), and an outward movement system 508.

[0073] The feed system 504 is operable to perform functions including, without limitation, feeding, transporting, guiding, pushing, positioning (in some embodiments, passing through) the material blank 501 to the bending device 506. Figure 5A -B, the feed system 504 may include a drive roller 510 having a feed roller 512 and a feed actuator 514. The components of the feed system 504 may be supported by a feed base 528, which may include a frame, which may be positionable. The drive roller 510 may feed the material blank 501 into the bending device 506, and the drive roller 510 may turn the material blank 501 into the bending device 506. The turning of the material blank 501 may be achieved by the feed actuator 514, which is capable of adjusting at least one of the following: the position of the material blank 501, the position of the drive roller 510, the position of the feed roller 512, the position of the feed base 528, and the position of the entire feed system 504. The feed actuator 514 is also capable of adjusting the angles of the aforementioned components in an embodiment. Other configurations of the feed system 504 are possible, including embodiments with a single drive roller (perhaps not a "roller" at all), embodiments with more or fewer actuators, or embodiments with other means for providing an adjustment mechanism to the feed system 504. In general, the feed system 504 may include a drive roller adjustment mechanism configured to adjust the position and angle of the drive roller 510. The combination of the feed adjustment mechanism and the drive roller adjustment mechanism may position the material blank 501. In embodiments, the feed system 504 may not impose constraints on the movement of the blank, and the material blank 501 does not have to rotate relative to any other point in the feed system 504.

[0074] Bending apparatus 506 may generally include a triple roller 516 having a top roller 518 and two bottom rollers 520. The rollers of triple roller 516 may generally include a roller row 522 including a plurality of rollers 524, which may be in the form of rollers.

[0075] The feed system 504 and the bending device 506 may be supported separately by their own frames, or may be on a single frame (not shown) that allows the feed system 504 and the bending device 506 to move together. Alternatively, either or both of the feed system 504 and the bending device 506 may be fixed. Moreover, either or both of the feed system 504 and the bending device 506 may be able to move independently. The support (and / or the single frame in the embodiment not shown) may be adjusted in many degrees of freedom, for example, in a direction parallel to the central axis of the flat-topped cone 502 (x direction, i.e., toward and away from the peak 503 of the cone 502), in a direction perpendicular to the central axis of the cone 502 (y direction, i.e., toward and away from the track 526 of the outward displacement system 508), up and down, (z direction) and rotation about the x, y and z axes, as well as rotating the frame about multiple axes (for example, if adjusting the roller position rather than the outward displacement position for gap control). Movement of these components may be achieved by means known to those skilled in the art, including (without limitation) hydraulic pistons, pneumatic pistons, servos, screws, actuators, rack and pinion systems, cable and pulley systems, cams, electromagnetic drives, robotic arms, rollers, drives, etc., or a combination of any of the foregoing or other devices capable of imparting the desired motion. In addition, although not described herein, subsystems of the components shown may be movable (e.g., certain arms and supports may be positioned in any manner conceivable to those skilled in the art).

[0076] Figure 6 600 (i.e., roll forming system). As described herein, in some embodiments, the bending device 600 includes a triple roller 602. The triple roller 602 may include a top roller 604, and two bottom rollers 606 (or conversely, a bottom roller and two top rollers - not shown). The top roller 604 may be articulated vertically - manually, or under the guidance of a bending device control system or other control system. Articulating the top roller 604 may be advantageous, for example, for engaging a material blank, or controlling the amount of curvature applied to the material blank when the material blank is conveyed through the triple roller 602. The bottom roller 606 may also or instead be articulated, for example, along an inclined surface 608 supporting the bottom roller 606, along another inclined surface or path, or along a curved surface or path. When the top roller 604 is moved, the bottom roller 606 may be moved for the same or similar purpose, for example, to more easily start feeding the material blank, and to control the diameter of the tapered structure being formed. In general, any of the rollers of the trio of rollers 602 may be articulated, and any controllable variation in the relative positions of the rollers may be used to impart a corresponding amount of curvature to the material blank.

[0077] In some embodiments, and as described above, the triple roller 602 includes a plurality of individual rollers 610 arranged in rows. Generally, the rows of rollers allow the material blank to travel through the triple rollers in a direction that is angled with the bending axis when the material blank is rolled, rather than vertical. For example, in a triple roller with three solid rollers, the direction of the bending axis is substantially parallel to the axis of the rollers, and the material blank is forced to move in a direction perpendicular to this direction due to the rotation of the rollers, so that the material blank is forced to roll back. Very large forces may be required to change this orientation. In order to continuously roll a cylindrical or tapered shape, the material blank should be able to be fed to the triple roller at an angle that allows the material blank to form a spiral, wherein a row of rollers may be utilized to do this.

[0078] When using rows of rollers, the bending axis can still be oriented substantially parallel to the row of rollers, while the material blank can be forced to move in the direction of the rollers. To illustrate the difference between using solid rollers and using rows of rollers, Fig.23 A first configuration 2300 is shown with a solid roller 2302. In the first configuration 2300, a material blank 2304 is fed through the solid roller 2302 along a first feed direction 2306, which may be perpendicular to a bending axis 2308. This may produce a first curved roll 2310 that is similar to the first configuration 2300 shown above (i.e., the direction of the bending axis 2308 is substantially parallel to the axis of the solid roller 2302, and the material blank 2304 is forced to move in a direction perpendicular to this direction due to the rotation of the solid roller 2302, so that the material blank 2304 is forced to roll back, as shown in the first curved roll 2310). Alternatively, as shown in the second configuration 2312, the angle of the rollers 2316 on the roller row 2314 may not depend on the position of the roller row 2314. Thus, the material blank 2318 can be fed at any angle relative to the bending axis 2320, as long as the direction of the material blank 2318 is generally along the rolling direction of the roller 2316. Thus, it may be advantageous to have the direction of advancement of the roller 2316 independent of the direction of the bending axis 2320 - the system may have the same bending axis 2320, but rotate the roller 2316 so that the feeding angle can be changed, which will change the angle of the spiral formed by the rolling of the material blank 2318. For example, the material blank 2318 can be fed along a second feeding direction 2322. This can produce a second curved roll 2324 that is similar to the second configuration 2312 shown above, i.e., a more spiral shape is produced by the first configuration 2300 than the first curved roll 2310. This can be advantageous for a substantially continuous rolling and welding process, where a blank of material is fed into a rolling machine at a desired angle and formed into a more or less spiral (i.e., it can be a spiral for a cylinder, and it can be a helical structure for a cone), and then the spirals are joined into a solid shape.

[0079] In various embodiments, the rollers may be driven individually, driven together, or not driven at all. Similarly, in various embodiments, the rollers may be driven individually, driven together, or not driven at all. The rollers may also be steered individually, steered together, or not steered at all. In an embodiment, the rows are substantially parallel. In another embodiment, the rows need not be parallel.

[0080] Back to Figure 6 In an embodiment, the bottom roller 606 is a lower roller row that is movable in both a translational and angular manner. That is, the bottom rollers 606 can be moved closer together and apart while remaining parallel, and their relative angles can also be changed so that, for example, the distance between corresponding rollers 610 of each roller row near the throat 612 of the bending device 600 can be greater than the distance between corresponding rollers 610 farthest from the throat 612. This can assist the system in forming tapered structures, as well as controlling the diameter and taper of the structure being formed. Figure 6 In the embodiment shown in FIG. 1 , actuation of the roller row is accomplished by four screw jacks 614 driven by electric motors, wherein the roller row slides on a low friction surface 616 between sets of guides 618. Those skilled in the art will recognize that other means of moving the roller row are possible, for example, the roller row can also be guided by profile rails, other types of rails, slides, bushings, linkages, etc., and actuation can be accomplished by ball screws, screw jacks, rack and pinion, belts, pistons, etc.

[0081] The relationship between the roll position (eg, roller row position) and the resulting radius of curvature of the tapered structure being formed will now be discussed.

[0082] Figure 7 An example showing the results of the model predicting the next roller row (e.g. Figure 8 In particular, Figure 7 A plot 700 is shown where the stock material is approximately 0.075" thick steel having a yield strength of approximately 50 ksi. This model 700, for example, could potentially be used along with empirical adjustments based on test results as the basis for a control system that continuously controls the diameter of the tapered structure being formed by substantially continuously adjusting the position of the row of rollers of a triple roll. This control system could be used with or without an additional feedback system.

[0083] In particular, Figure 7A plot 700 is shown that includes example model results for the relationship between roller row positions and the resulting radius of curvature of a tapered structure being formed. Plot 700 includes the distance between the bottom rollers (e.g., the bottom roller row) in a triple roller roll along an x-axis, where the x-axis includes a distance of 7-13 inches. Plot 700 further includes the radius of curvature of the tapered structure being formed along a y-axis, where the y-axis includes a radius of curvature of 0-20 inches.

[0084] Figure 8 800, including two bottom rollers 802 and a top roller 804, wherein the rollers may be a roller row. A first arrow 806 and a second arrow 808 represent the bottom rollers 802 moving away from each other along inclined surfaces 810, 812. A first double-headed arrow 814 represents the distance between the bottom rollers 802. A second double-headed arrow 816 represents the distance between the bottom roller 802 and the top roller 804.

[0085] As stated above, in embodiments, the degree of curvature applied by the bending device (e.g., triple rollers) may be continuously controlled. To form a conical or truncated conical structure, for example, the curvature that may be deformed at a given point on the incoming material blank may vary linearly with height along the axis of the resulting cone (on which the given point will be located). Other tapered structures may include other degrees of applied curvature. Figure 7 and 8 The roller or roller row of the triple rollers is shown as being adjustable to control the diameter of the tapered structure. In an embodiment, the top roller 804 is fixed in place and the two bottom rollers 802 are moved (i.e., in the directions shown by arrows 806, 808) to change the relative distances between the three rollers. The bottom rollers 802 are movable along the inclined surfaces 810, 812, as shown in FIG. Figure 8As shown in the figure. As shown in the figure, the distance between any one of the bottom rollers 802 and the top roller 804 can change when the distance between the bottom rollers 802 changes, because the bottom rollers 802 are on the inclined surfaces 810, 812, and the top roller 804 can be fixed. That is, in this example, the greater the distance between the bottom rollers 802, the smaller the distance between each bottom roller 802 and the top roller 804. On the one hand (for example, for shallow slopes), when the bottom rollers 802 move away from each other, the amount of curvature obtained when the material blank is transferred between the rollers is smaller, and when the bottom rollers 802 move closer, the material blank obtains a greater curvature. The inclined surfaces 810, 812 can allow the system to be less sensitive to roller positioning errors-because when the bottom rollers 802 move away from each other, they move closer to the top roller 804, thereby reducing the impact of their movement on the diameter of the roll relative to the movement along the flat surface. On the one hand, having a steep enough slope that the bottom rollers 802 move away from each other making the roller diameter smaller is also feasible because due to the steep slope, the bottom rollers 802 will not be as far away from each other, but will be closer to the top roller 804.

[0086] Sheet turning (ie, turning the material blank) will now be discussed.

[0087] In general, sheet steering can be achieved using components of the feed system and / or rolling assemblies. In addition to controlling the diameter of the tapered structure being formed, the system can also include controlling the feed angle at which the material blank is fed into the bending device. This can be achieved in many ways. In general, there should be at least two degrees of freedom - that is, it is typically not enough to control the feed angle (e.g., a system that can swing the feed base, such as those in a cylindrical spiral milling cutter) without controlling the material position. The embodiments shown in the figures included herein (see, for example, Figure 5A -B) Use a combination of an actuated drive system and steerable rollers to achieve the desired feed motion.

[0088] Sheet deflection helps prevent gaps from forming in the tapered structure. Fig. 9 An example of a gap in a tapered structure is shown in . In particular, Fig. 9 A tapered structure 900 with a clearance error 902 and a tapered structure 904 without a clearance error are shown.

[0089] In general, a piece of blank can be fed into a bending device (e.g., a triple roller) at the correct angle and position to form the desired tapered structure with no gaps or overlaps between turns. As used in this disclosure, those skilled in the art will understand that "no gap" (or similar) includes blanks with intentionally controlled gaps, such as for welding, etc. Fig.10An example of a tapered structure 1000 formed by feeding a material blank at different angles is shown. Note that Fig.10 depicts a cylinder, but it will be referred to as tapered structure 1000 because Fig.10 The same principles apply to tapered structures and cylinders. The cylinder is used only to make it easier to clearly illustrate the relationships discussed below (e.g., with a cylinder, a straight sheet has the same feed angle, while with a tapered structure, the feed angle changes as it rolls, so the relationship below may not be visible at the specific moment when the tapered structure is used). Fig.10 The tapered structure 1000 when the material blank 1002 is fed into the bending device at the correct angle, the tapered structure 1004 when the material blank 1002 is fed into the bending device at too steep an angle, and the tapered structure 1006 when the material blank 1002 is fed into the bending device at too shallow an angle. Fig.10 As shown by the tapered structure 1006 in FIG. 1 , a shallower feed angle allows a blank 1002 to wrap more tightly around itself, thereby creating an overlap 1008. Fig.10 As shown by the tapered structure 1004 in FIG. 1 , a steeper feed angle can cause the winding section of the blank 1002 to be farther apart, thereby likely creating a gap 1010 between the corresponding edges 1012, 1014 of the blank 1002. The correct feed angle allows the blank 1002 to be wound into the desired shape while maintaining the desired gap for joining the edges of the blank (see FIG. 1 ). Fig.10 For tapered structures, this feed angle can be changed when the blank is fed into the bending device. Some techniques described herein include a control system that can change the feed angle (and other parameters described herein) so that the edges of the blanks are adjacent to each other, thereby allowing them to be joined (e.g., metal sheets with edges welded together) to form the desired structure 904, 1000, such as Fig. 9 and 10 As shown in the respective.

[0090] According to one aspect, the control system is able to change the feed angle by controlling the approach of the material blank so that when the blank is fed into the bending device, the blank purely rotates (i.e., does not translate) relative to the apex of the tapered structure. This condition is equivalent to making the distance between each point on the incoming sheet blank and the apex of the tapered structure consistent when the blank is fed into the bending device. However, the apex of the tapered structure itself may move relative to other components of the system, as described more fully below. The purely rotational condition described above only involves the relative movement of the fed blank relative to the position of the apex. That is, both the blank and the apex may also translate relative to other components of the system or undergo more complex movements. If this condition is met, even irregularly shaped blanks can be connected into a tapered structure.

[0091] As discussed above, the feed system can feed the blank material into the bending device. Embodiments include a feed control system that controls the feeding of the blank material into the bending device by controlling the feed system. The feed control system can control various aspects of the feeding of the material blank into the bending device, including (but not limited to) the feed speed, the feed angle, the direction of the feeding material (e.g., into or out of the bending device), the feed force, the position of the material blank, the position of various components of the feed system, the offset of the components of the feed system and / or the material blank, etc. In some embodiments, the feed system includes one or more positioners, slides, articulated arms, rollers, etc., which feed the blanks into individual sheets into the bending device, and each of them can be controlled by the feed control system together to ensure that the desired feeding conditions are met.

[0092] Back to Figure 5A and 5B In some embodiments, the feed system 504 includes a drive system, which may include a drive roller 510 having a feed roller 512. The feed roller 512 may be driven separately by a drive system control system, which may be a component of the entire control system or independent of other control systems. In particular, the feed rollers 512 may be driven differently by the system control system (e.g., some feed rollers 512 are driven at different rates than other feed rollers 512) so that the blank is rotated when it is conveyed through the feed rollers 512. Controlling the rotational speed of the feed rollers 512 (in combination with other parameters described herein) may help the material blank 501 achieve rotational movement around the peak of the flat-topped cone 502 to be formed. The feed rollers 512 may be used together with a bending device having a steerable roller to steer the material blank 501 in a desired rotational manner.

[0093] exist Figure 5A In the embodiment shown in FIG. 1-B, the feed system 504 is capable of translating in a direction parallel to the axis (i.e., the bending axis) of the top roller 516 and rotating in a plane. The feed system 504 can be freely rotated by a turntable (not shown; located at Figure 5A The back of the material blank 501 and Figure 5B The turntable can then be supported by bearings (also not shown; located at Figure 5A The feed system 504 may be supported at the rear (i.e., further away from the bending device 506) by an air bearing 530 (or other low friction motion device) that supports the feed system 504 while allowing it to rotate and translate with low friction.

[0094] exist Figure 5A-5B In the embodiment shown in, at least two feed actuators 514 acting as feed adjustment mechanisms can be used to control the position of the feed system 504 (but other number and form of positioners can be used). The feed actuators 514 can be operated together to set the position of the feed system 504 along the x-axis line, and to set the angle of the feed system 504, which can be completed under the control of the feed system control system. The feed actuator 514 may include a hydraulic piston, a pneumatic piston, a servo, a screw, an actuator, a rack and pinion, a cable and pulley system, a cam, an electromagnetic drive or other devices that can provide the desired motion. The motion of the feed system 504 controlled by the feed actuator 514 (combined with other parameters described herein) can help the material blank 501 to realize rotational motion around the peak 503 of the flat-topped cone 502 during the construction process.

[0095] To assist in controlling the movement of the material blank 501, the individual rollers 524 of the roller row 522 in the triple roller 516 can be controlled in a variety of ways. In some embodiments, the individual rollers 524 can be steered by the control system. That is, the direction of movement applied by the rollers 524 to the material blank 501 can be controlled by setting the angle of the individual rollers 524 relative to the chassis of the triple roller 516. In particular, the rollers can modify the movement applied by the feed system 504 to the material blank.

[0096] In some embodiments, the roller 524 is fixedly mounted, but the rotational speed of the rollers of the roller 524 is controllable. In some embodiments, controlling the relative speed of the rollers of the roller 524 can jointly cause the material blank 501 to rotate around the peak 503 of the flat-topped cone 502.

[0097] Fig.11A A system 1100 is depicted for turning a sheet using a driven roller 1102 and an array 1104 of steerable rollers 1106. In particular, Fig.11A A schematic diagram of a system 1100 is shown by which rotational motion 1110 can be provided to a sheet of blank 1108 using a system having a positionable drive system (e.g., positionable drive roller 1102) and a steerable roller 1106. The rolling direction of roller 1106 is shown by a first arrow 1112 (where the rolling direction may be slightly different for each roller 1106), and the rolling direction of drive roller 1102 is shown by a second arrow 1114. Additionally, Fig.11AShown is a contact area 1116 on roller 1106 (i.e., where roller 1106 can contact blank 1108, which can be a very small area, for example, if roller 1106 includes a crowned roller), a contact area 1118 on drive roller 1102 (i.e., where drive roller 1102 can contact blank 1108), a line 1120 extending from contact area 1116 of roller 1106 perpendicular to first arrow 1112, and a line 1122 extending from contact area 1118 of drive roller 1102 perpendicular to second arrow 1114. In an embodiment, if there is no (or negligible) slip, the sheet of blank 1108 will be driven along the rolling direction of all rollers in the system, including drive roller 1102 and individual rollers 1106 (i.e., in the direction of first arrow 1112 and second arrow 1114). In general, it may only be necessary to have two non-parallel rollers to implement this system 1100. That is, when the blank 1108 in the form of a single sheet is acted upon by two non-parallel rollers, the only way it can move along the rolling direction of the two rollers without slipping is to rotate. In particular, the blank 1108 in the form of a single sheet can rotate about a point 1124 located at the intersection of lines 1120, 1122 passing through the contact areas 1116, 1118 and perpendicular to the rolling directions 1112, 1114, such as Fig.11A If there are more than two rollers in the system (e.g., row 1104 is shown with multiple rollers 1106), the rollers should be positioned so that there is only one center of rotation, otherwise slippage may occur at one or more of the rollers and control of the movement of the blank 1108 will be poor. Fig. 11B 1124. In other words, if at least two drive rollers 1102 are used, the relative speeds of the drive rollers 1102 should be adjusted so as to maintain rotation around a single point 1124. In particular, the speed may be proportional to the distance of each drive roller 1102 from the axis of rotation. Moreover, the angles of the rollers 1106 should be compatible with each other and with the drive rollers 1102, for example, in order to maintain rotation around a single point 1124. In general, the components of the system (which may include all components cited in this document) can be adjusted with the goal of causing the material blank to rotate more or less around a single point. In other words, it may be impossible to completely align the material blank and the components of the system (for example, there may always be some slippage), so the components are adjusted in order to try to obtain the best alignment in which the material blank rotates more or less around a single point.

[0098] For example, you can refer to the above Figure 3 , 4A The rotation of the roller row is achieved by rotating the cam plate as described in 4B.

[0099] The embodiments herein use a variety of structures - positioners, single rollers, paired or system rollers, etc. - to move the material blank, or help move the material blank, so that the end result is that the material blank moves rotationally relative to the peak of the tapered structure when the material blank moves through the bending device. These embodiments only illustrate a few of the virtually infinite possibilities for achieving this result. In particular, the foregoing embodiments illustrate the full scope of the present invention in an inexhaustible manner. In addition, even for equipment of a particular construction, there may be more than one way to control multiple components in general, so that the net effect is to move the blank rotationally around the peak of the tapered structure on the way to the bending device. Other control techniques can be easily identified.

[0100] Embodiments of a gap control system will now be described. As used in this disclosure, "gap control system" shall mean any control system for correcting alignment errors of edges of a material blank when joining the edges of the material blank, correcting gaps between the edges of the material blank when joining the edges of the material blank, and generally positioning a machine and / or a material blank and / or a tapered structure after the material blank has rolled through a portion of a bending device.

[0101] Even if the material blank is correctly fed through the bending device (e.g., bending rollers in a triple roller), it may be beneficial to correct small errors in alignment and gaps between the corresponding edges of the material blank after the edges are rolled and before they are joined together. This may be due to differences in the geometric configuration of the material blank sheets, for example, due to tolerances in the material forming process, small errors in the feed turning, small errors in the rolling process, etc. It may be beneficial to have an additional system to account for gap and alignment errors after rolling and before the edges of the material blank are joined together.

[0102] One purpose of the gap control system is to control the gap and alignment between the blank sheet of material and the partially completed tapered structure when they are joined together. For example, there may be at least three errors to be resolved: in-plane gap error, out-of-plane gap error, and tangency alignment error. However, those skilled in the art will appreciate that the gap control system may be used to resolve more or fewer errors, or any combination thereof.

[0103] exist Fig. 12A and 12B An example of in-plane gap error is shown in . Fig. 12A An example of a non-error tapered structure 1200 (e.g., a flat-topped cone) is shown, while Fig. 12B The tapered structure 1200 in FIG. 1 includes a gap error. Fig. 12A and 12B The first arrow 1201 in points to the same position, where there is Fig. 12B The error in the weld gap can be 1202. Fig. 12A In FIG. 1 , the gap 1204 is uniform and the blank 1206 of material to be joined (eg, welded) is aligned with the existing shape. Fig. 12B In FIG. 1204 , there is an in-plane gap error 1202, which means that after the join is completed at this location, the material blanks 1206 to be joined are set at an angle so that the gap grows. Errors can also occur if the gap shrinks and causes or will cause overlap, and if the gap is in the "plane" of the existing curvature - that is, the rolled material has the correct curvature to match the part that has been joined, but is too far (or too close).

[0104] exist Fig.13A and 13B An example of out-of-plane gap error is shown in . Fig.13A Showing an error-free example ( Fig.13A and 13B Depicting a cylinder 1300 rather than a cone makes it easier to see the error when viewing the structure from the end. Fig.13A , the cross section shown as seen from the end looks like a perfect circle because everything on the cylinder 1300 is aligned. Fig. 13B A cylinder 1300 is depicted showing an example of an out-of-plane gap error 1302. The out-of-plane gap error 1302 occurs because after the join is completed at this location, the material blank 1306 to be joined bends away from the existing cylinder, thereby opening up a gap 1304 that is out of the "plane" of the surface of the cylinder 1300 and causing a ridge, bump, depression (e.g., bowing inward to create a depression, etc.), or other surface error on the surface of the tapered structure.

[0105] exist Fig.14A and 14B An example of tangency alignment error is shown in . Fig.14A An example of an error-free tapered structure 1400 (e.g., a flat-topped cone) is shown, while Fig. 14B The tapered structure 1400 in the embodiment includes a tangency misalignment 1402. The tangency misalignment 1402 does not necessarily include a gap, but may include an misalignment between the sheet surface 1404 to be joined and the existing sheet surface 1406 in the tapered structure 1400. Fig. 14B Such errors occur when the surfaces are mismatched, as depicted in . In other words, if the errors are allowed to remain and the sheets are joined in place, the final structure (eg, a wind turbine tower) will appear to be curved, or will have recesses, protrusions, etc.

[0106] The gap and alignment may be measured near the joining location, with the goal of measuring at a distance that may be upstream of the join so that adjustments can be made before joining. Measurement methods may include (but are not limited to) measuring laser line scanners (similar laser systems are used in gap-compliant automatic welding systems), contact sensors (such as LVDTs, etc.), vision systems using video cameras, etc. It is also feasible to use a laser line scanner to measure the position of one edge that is farther from the join, for example. In this case, only one edge may be measured, without measuring the gap.

[0107] An embodiment of the outward shifting system will now be described. In general, gaps and mismatches can be corrected by translating and / or rotating an already formed tapered structure relative to the rollers but not relative to a linked sheet held in a bending apparatus (e.g., a triple roller). To do this, either the rolled and linked tapered structure or the rolled but unlinked sheet can be manipulated. One possible way to accomplish this may be to hold the tapered structure in an outward shifting system that supports the tapered structure after it has been linked and translates and rotates the bending apparatus while the bending apparatus holds the rolled but unlinked sheet. Another way to accomplish this may be to leave the bending apparatus stationary and use the outward shifting system to manipulate the rolled and linked tapered structure.

[0108] The outward movement system may have multiple mechanisms intended to prevent and / or correct the errors discussed herein. In an embodiment, the outward movement system has at least two subsystems - an "in-machine" subsystem and an "out-machine" subsystem. The in-machine subsystem may be provided close to the bending device and the connecting element. The out-machine subsystem may be provided close to the end of the tapered structure being formed and support the end.

[0109] Fig.15 and 16 A general diagram showing an embodiment of the subsystems of the outward movement system, wherein Fig.15 Displays the internal subsystem 1500, and Fig.16 The external subsystem 1600 is displayed.

[0110] like Fig.15 , the in-machine subsystem 1500 can support the tapered structure 1502 (e.g., a flat-top cone) being formed, which can prevent the triple roller 1504 from having to support its own weight. The in-machine support mechanism 1506 can have an adjustable height, which can be used to address out-of-plane gap errors or tangency errors. For out-of-plane gap errors, the in-machine subsystem 1500 and the out-of-machine subsystem 1600 (which can also move up and down in embodiments) can move up and down together, so that the slope of the tapered structures 1502, 1602 remains substantially the same, but the out-of-plane gap is changed. For tangency errors, the in-machine subsystem 1500 and the out-of-machine subsystem 1600 can move vertically relative to each other, thereby changing the angle of the tapered structures 1502, 1602.

[0111] The in-machine support mechanism 1506 may include supports, such as support rollers 1508 and the like (e.g., pads, sliders, bearings, shock absorbers, etc.). The support rollers 1508 may be positioned by control (automatic or manual), or they may be passive. The supports may include shock absorbers and the like, and they may pivot around a pivot point on a vertical support. The support rollers 1508 may allow the tapered structure 1502 to rotate easily relative to the support rollers 1508. The support rollers 1508 may be cylindrical, spherical (e.g., because the direction of the surface of the tapered structure 1502 relative to the angle of the support rollers 1508 changes when the diameter of the tapered structure 1502 changes, a spherical roller may account for this change), etc. The supports may be disposed on an axle 1510 or the like, wherein the axle 1510 may move laterally (left and right). Additionally or in the alternative, the support members may be disposed on rails 1512 that allow support rollers 1508 or the like to move laterally. For example, shaft 1510 may include a ball screw or the like, wherein support rollers 1508 may slide along rails 1512 and be positioned by the ball screw. The position of support rollers 1508 along the ball screw may determine the height of support rollers 1508, and thus the height of tapered structure 1502. This degree of freedom may also be used to passively adjust for positional changes of tapered structure 1502 being formed. Additionally or in the alternative, the degree of freedom that may be used to passively adjust for positional changes may be used to move support structure 1506 laterally on rails 1512 as a whole. The supports may move together to adjust the position of tapered structure 1502, or they may move relative to each other to adapt to a varying diameter of tapered structure 1502, and / or to apply a force to tapered structure 1502. The supports may be passive, or they may include one or more actuators, etc., to control lateral movement of the supports. The actuators may be used to control the horizontal and / or vertical position of the tapered structure 1502 by moving the supports relative to each other (e.g., in an embodiment, the tapered structure 1502 is higher if the supports are closer to each other). The actuators may also or instead be used to control the left / right position of the tapered structure 1502 by moving the supports together.

[0112] like Fig.16 As shown in FIG. 1 , offboard subsystem 1600 may support end 1604 of tapered structure 1602 and may include mechanisms for accounting for gap and alignment errors. Some of these mechanisms are described below.

[0113] The off-board support 1606 of the off-board subsystem 1600 can move up and down. This (in conjunction with the height adjustment of the on-board subsystem 1500) can account for out-of-plane clearance errors. This movement can also be used to account for tangency errors—for example, when the height of the on-board subsystem 1500 remains fixed, adjusting the height of the off-board support 1606 can change the angle of the tapered structures 1502, 1602 so that it can be aligned.

[0114] The off-board support 1606 of the off-board subsystem 1600 can move laterally (perpendicular to Fig.16 This movement can be used to correct for in-plane gap errors.

[0115] The outboard support 1606 of the outboard subsystem 1600 can be used to rotate or twist the tapered structure 1602 about its axis. This twisting is another way to correct out-of-plane errors, that is, twisting can be used to "roll up" or "loosen" the sheets to be connected, thereby changing their diameter and aligning them. The outboard subsystem 1600 can also actively control its movement away from the bending device when the tapered structure 1602 is formed. For example, another possible degree of freedom is to control the outboard trailer 1610 to move along the track 1608. This control can potentially solve the in-plane gap by moving the tapered structure 1602 toward and away from the bending device (which can open and close the gap). This movement can also provide a force to the tapered structure 1602, which can be a push toward the bending device or a pull away from the bending device. The trailer 1610 can also include a brake, which can be an actively controlled brake. Moreover, the embodiment can include a passive outward movement system. Those skilled in the art will appreciate that components of off-board subsystem 1600 may be used to correct for errors other than those specifically mentioned herein. For example, raising and lowering off-board support 1606 may correct for both in-plane and out-of-plane errors. Additionally, components of other systems described herein may be used to correct for errors other than those specifically mentioned herein.

[0116] In an embodiment, the outboard support 1606 is as follows Fig.16 As shown in FIG. 1 , the outboard support member is disposed near the end 1604 of the tapered structure 1602. However, in other embodiments, the outboard support member may be disposed at other locations (not shown), including but not limited to near the center of the tapered structure or near the end of the tapered structure closest to the bending device.

[0117] Outboard support 1606 may include vertical support column 1612 and horizontal support arm 1614, wherein support column 1612 engages with trailer 1610. At the end of horizontal support arm 1614 there may be a conical engagement mechanism 1616 that includes a support structure for supporting tapered structure 1602 and / or grabbing tapered structure 1602.

[0118] In an embodiment, the conical engagement mechanism 1616 is locked to the tapered structure 1602 so that it can move and / or twist the tapered structure 1200 without moving outwardly therewith. This can be achieved by a spindle or spindle-like structure, and / or using clamps, bolts, cables, clips, couplings, docking parts, pins, friction fits, clamps, hooks, joints, latches, locks, bumps, pins, screws, sliders, snaps, etc. For example, a gripper can be provided that supports the tapered structure 1602 from the inside and allows it to rotate. The gripper can be controlled to lock the tapered structure 1602, release the tapered structure 1602, rotate the tapered structure 1602, etc.

[0119] The off-board subsystem 1600 may include a trolley 1610 that allows the off-board subsystem 1600 to be moved. The trolley 1610 may include wheels 1618, etc. that may slide along tracks 1608, etc. Embodiments may include only wheels 1618, etc. without any tracks (not shown). The trolley 1610 may also include or instead include a slider that may slide along the track or slide freely (i.e., on the floor). The slider may include a mechanism for reducing sliding friction, such as a low friction material (e.g., Teflon), grease, rolling element bearings, air bearings, etc.

[0120] Additional embodiments of the control system will now be discussed.

[0121] The construction system for forming a tapered structure described herein may include a control system that can control one or more components of the construction system. For example, the control system may include a sensor, or multiple sensors, and the sensor provides feedback about the component or multiple components of the construction system and / or the tapered structure being formed. The construction system may include one or more adjustment mechanisms, and the adjustment mechanism can automatically position the component or multiple components of the construction system and / or the tapered structure being formed. Unless otherwise expressly indicated, or clearly understood according to this article, as used herein, adjusting the material blank or adjusting the tapered structure should include any adjustment to the material at any stage during the construction of the tapered structure (before the tapered structure is formed, during the formation, after the formation). Automatic positioning can be based on feedback obtained from the sensor, and / or can be based on a model used to form a desired tapered structure. For example, in an embodiment including a triple roller, the adjustment mechanism can automatically position at least one roller in the triple roller to adjust the shape of the tapered structure being formed. Automatic positioning allows the diameter of the structure being formed to be changed substantially continuously so that it tapers. The adjustment mechanism may include any means known to those skilled in the art, including (without limitation) hydraulic pistons, pneumatic pistons, servos, screws, actuators, rack and pinion systems, cable and pulley systems, cams, electromagnetic drives, robotic arms, rollers, drives, etc., or any combination of the foregoing or other devices capable of providing the desired motion.

[0122] Feedback from the sensors may be provided to a computer and / or controller, which may then send a signal to an adjustment mechanism (or mechanisms) to automatically position a component of the build system, such as one of the triple rollers. The feedback may include many different types of feedback, including, but not limited to, one or more of the following: the position of a component of the build system (e.g., one of the triple rollers, and / or the distance between at least two of the triple rollers, the angle of a component of the build system relative to another component and / or the tapered structure being formed, etc.), geometric data of the tapered structure being formed (e.g., diameter, radius of curvature, taper angle, in-plane weld gap, out-of-plane weld gap, edge location, distance of the "center" of any section of the tapered structure from the axis of the tapered structure, etc.), force data (e.g., the force required to complete the action of the machine for forming the tapered structure, including, but not limited to, closing the weld gap, straightening the tapered structure to obtain tangency, adjusting the angle of at least one of the plurality of rollers, moving at least one of the plurality of rollers, and driving the material blank into or through the machine for forming the tapered structure), etc.

[0123] The control system may further include a model for forming a tapered structure. The model may be a mathematical and / or computer model. The model described herein may include an empirical model (e.g., a purely empirical model), a model based on a lookup table, a model of a basic concept, or any combination of these models. The model output may be based on theoretical or mathematical analysis, empirical measurements, fitting factors, other factors, and / or other parameters that may affect the operation of the machine. The model may calculate results during machine operation. The model may include previously calculated results, which have been stored, and then accessed during machine operation. The model may include the position of one or more components of the build system (e.g., the position of the rollers included in the triple rollers). The model may also include or instead include geometric information of the tapered structure being formed. The geometric information may include the position of the coordinates and / or features of the tapered structure relative to one or more components of the build system and / or relative to each other. The model may include a model of the ideal edge position of the material blank, wherein the model includes the position of the bending device and the tapered structure based on the feedback provided by the edge position sensor. The adjustment mechanism may be configured to automatically position one or more components of the build system (e.g., at least one roller of the triple rollers) based on the output from the model. The adjustment mechanism may also be configured to automatically position one or more components of the build system based on a combination of feedback from the sensors and the model.

[0124] The adjustment mechanism or mechanisms may be configured to position one or more components of the build system (e.g., at least one roller of a triple roller) along an inclined path. The adjustment mechanism or mechanisms may be configured to position one or more components of the build system (e.g., at least one roller of a triple roller) along a curved path. The adjustment mechanism or mechanisms may be configured to position the angle of one or more components of the build system (e.g., at least one roller of a triple roller). The adjustment mechanism or mechanisms may be configured to position the tapered structure in any manner described herein or in a manner that would be reasonably apparent to one of ordinary skill in the art.

[0125] The building system may include a triple roller, wherein the triple roller includes three roller rows, and the roller rows include a plurality of individual rollers, which in embodiments may include rollers. The adjustment mechanism may be configured to adjust the angle of the roller row. The adjustment mechanism may be configured to adjust the angle of the plurality of rollers. It may be possible to steer each individual roller, and the adjustment mechanism or mechanisms may be configured to perform the steering.

[0126] The adjustment mechanism may be configured to independently position the rollers of the triple roller. For example, there may be a plurality of adjustment mechanisms, each of which is configured to position a corresponding roller of the triple roller.

[0127] Embodiments may include a material blank for forming into a tapered structure, wherein the material blank is fed into a machine for forming a tapered structure and formed into the tapered structure by a triple roller. An adjustment mechanism may be configured to automatically adjust the angle of at least one set of rollers to keep the material blank in a proper position for forming into the tapered structure. The adjustment mechanism may be configured to automatically adjust the angle of at least one set of rollers to compensate for slippage of the material blank.

[0128] In an embodiment, a feed system receives a blank material from a blank material source, a rolled blank sheet, a box of blanks, etc. to a bending device. Thus, the feed system and the bending device together can obtain a material blank and bend the material into a desired shape, which can be a substantially conical shape, the radius of which varies over its length. In an embodiment, the bending device includes a triple roller, wherein the triple roller includes at least three roller rows, the roller rows including a plurality of rollers. The three roller rows of the triple roller may include at least two bottom roller rows, wherein the bottom roller row serves as an inlet roller row and the other serves as an outlet roller row. In an embodiment, the inlet and outlet roller rows are movable so as to control the shape of the material being formed. Controlling the shape of the material being formed can be achieved by controlling the diameter of the material being formed.

[0129] The control system of an embodiment includes feedback, which can be based on any one of a number of criteria, or any combination of criteria. For example, the feedback can be based on geometric data. The geometric data can be obtained from the shape being formed, which can be a tapered structure (e.g., a cone). The geometric data can include (but is not limited to) diameter, radius of curvature, taper angle, weld gap (which can be a gap in the plane of the materials being joined or a gap outside the plane, or both), and a measurement of the distance of a portion of the tapered structure from the axis of the tapered structure (the distance can be measured from the "center" of any portion to the axis). Any one of these measurements can be used, or any other combination of these measurements can be used as feedback for the control system.

[0130] Feedback may also include geometric data from one or more components of the bending device, including (but not limited to) rollers, rollers, roller rows, rollers, positioners, wheels, drive systems, etc. Feedback may also include geometric data from one or more components of the feed system or outfeed system described herein, or as may be contemplated according to the present disclosure. This geometric data may also include correlation data between different components, such as distances between components, angles between components, etc.

[0131] In embodiments, feedback may also include or instead include force data. The force data may be obtained from the shape being formed, which may be a tapered structure (e.g., a cone). The force data may also include or instead include force data obtained from components of the build system. Examples of force data include, but are not limited to, the forces required to possibly accomplish an action of the build system to form a tapered structure, such as the force required to close a weld gap, the force required to straighten a tapered structure for tangency, the force required to adjust a roller or roller angle, the force required to move a roller or rollers, the force required to drive material into or through the build system, and the like. Any one or all of these forces may be used, or any other combination of these forces may be used as feedback for the control system.

[0132] In an embodiment, feedback data is obtained by sensors. A wide variety of sensors may be usefully incorporated into the control systems described herein, as will be readily apparent to one skilled in the art. For example, sensors may include, but are not limited to, position sensors (e.g., edge position sensors), angle sensors, displacement sensors, distance sensors, velocity sensors, acceleration sensors, optical sensors, light sensors, imaging sensors, pressure sensors, force sensors, torque sensors, level sensors, weight sensors, proximity sensors, presence (or absence) sensors, magnetic sensors, radio sensors, acoustic sensors, vibration sensors, and the like. Sensors may include angle sensors or many sensors.

[0133] The sensor may also include an imaging device and image processing circuitry to capture images of the tapered structure being formed or the components of the building system, and analyze the images to evaluate the shape, position, etc. of the tapered structure being formed or the component building system. The sensor may also include or instead include at least one video camera. The video camera may generally capture images of the building system and / or the tapered structure being formed. The video camera may provide a remote video feed via a network interface, and the operator may obtain the video feed via a user interface, which is maintained by, for example, remote hardware (such as a server) or maintained within a web page provided by a network server.

[0134] The build system may include sensors that detect the position of the material blank along the build path (from the feed system to the bending device to the outfeed system) or at any area of ​​the system.

[0135] The sensors may also include more complex sensing and processing systems or subsystems, such as a 3D scanner using optical techniques (e.g., stereo imaging, or shape from motion imaging), structured light techniques, or any other appropriate sensing and processing hardware that can extract 3D information from the build system and / or tapered structure. On the other hand, the sensors may include a machine vision system that captures images and analyzes the image content to obtain information, such as the state of the tapered structure being formed. The machine vision system may support a wide variety of imaging-based automated inspection, process control, and / or machine guidance functions for the build system, including (without limitation) pass / fail decisions, error detection (and corresponding audible or visual alarms), shape detection, position detection, orientation detection, collision avoidance, and the like.

[0136] In an embodiment, the sensor provides feedback including the radius of the tapered structure being formed. The build system can then be controlled by the control system to maintain a substantially continuous radius adjustment to the tapered structure to form a substantially conical object. In other words, the radius adjustment can be automatically controlled to produce a continuously varying diameter, as would be done for a tapered shape.

[0137] Embodiments include an adjustable triple roll row for rolling a tapered cone. Embodiments include substantially continuously adjusting the machine, which may include adjusting the triple roll row during the rolling process to substantially continuously adjust the diameter of the tapered structure being formed. The diameter of the tapered structure being formed may be changed by moving the rolls, where moving the rolls may be a reaction to the changing diameter.

[0138] Embodiments may include controlling the angle of the rollers themselves. The triple rollers used to form the tapered structure may include a roller row including a plurality of individual rollers or rollers. These roller rows may replace the rollers in a conventional roll bending process. In embodiments, the angle of advance of the individual rollers may be diverted, and in embodiments, the rollers may be actively and continuously diverted, thereby providing continuous control of the motion of the blank. In embodiments, the rollers are also used to divert the material as it is conveyed through the triple rollers.

[0139] The roller angle can be controlled for the following reasons. The triple rollers (interfacing with the material / sheet blank via the rollers) are one of the means for controlling the overall motion of the incoming feed blank and the tapered structure being formed. By properly steering the rollers (alone, or in combination with other modules), the incoming feed blank performs a specific motion for rolling the tapered structure.

[0140] In an embodiment, the rollers can be steered to control the weld gap. In an embodiment, the rollers can be steered to shift the blank toward or away from the throat of the triple rolls to maintain proper sheet position within the triple rolls. The rollers can also be steered to compensate for side slip.

[0141] The roller groups can be individually steered by motors, gears, racks, cams, linkages, screws, chains, belts, hydraulics, pneumatics, magnetics, manual means, friction drives, traction drives, heat, etc.

[0142] All or some of the rollers in a row may be steered together, but at angles independent of each roller. In particular, in embodiments, for rollers driven together, each individual roller angle corresponds to an angle specific but not identical to all other rollers. The roller groups may be steered by motors, gears, racks, cams, linkages, screws, chains, belts, hydraulics, pneumatics, magnets, manual means, friction drives, traction drives, heat, etc.

[0143] All or some of the rollers on a particular roller row may be steered together through the same angle. These roller groups may be steered by motors, gears, racks, cams, linkages, screws, chains, belts, hydraulics, pneumatics, magnets, manual means, friction drives, traction drives, heat, etc.

[0144] In an embodiment, the cam plate described above may be used to turn the rollers on a particular roller row. The cam plate may have different profiles for each cam, thereby producing different movements for each roller, or may produce the same profile for one or more cams, producing the same turning movement for the corresponding rollers. The profile in the cam plate may correspond to the desired roller movement (based on the model) to roll a particular cone. Alternatively, the profile may correspond to another relationship between the cam plate position and the roller angle that allows the control system to adjust the roller angle, that is, there may be a linear relationship (a certain distance of cam movement will cause the roller advance angle to change proportionally), etc. In an embodiment, one or all of the feed positioning system, the bending device positioning system, and the outward displacement positioning system may be used to control the distance and angle between two corresponding edges of the blank when the edges are connected. In an embodiment, the tapered structure formed and connected is kept fixed in the outward displacement system, and the bending device and a portion of the blank held in the bending device are positioned relative to the structure formed and connected. The bending device can translate relative to the structure formed and connected so as to close the in-plane gap between the edges of the blank so that they can be connected. The bending device can also be rotated relative to the formed and attached structure, for example, to close out-of-plane gaps and correct tangency mismatches between edges.

[0145] Fig.17 A flow chart 1700 is shown of a method for adjusting a weld gap according to an embodiment.

[0146] As shown in step 1702, the method may include feeding the material blank into and through the bending device. Feeding the material blank may be achieved by any means described herein, including (without limitation) a feed system, which may include a drive roller and a feed adjustment mechanism. The bending device may include a triple roller.

[0147] As shown in step 1704, the method may include detecting the position of the material blank. This may include detecting at least one edge of the material blank. The detection may be made by a sensor. Additionally or alternatively, this step may include detecting the position of a component of a feeding system or a bending device.

[0148] As shown in step 1706, the method may include determining whether the position indicates an undesirable gap condition. This step may include sending the position to a gap error controller, where the controller determines whether the position indicates an undesirable gap condition. This determination may also be achieved by comparing the sensed / detected position to a known ideal position, where the known ideal position may be part of a model, a known measurement, a predetermined value, a position from a previous run of the system or method. An undesirable gap position may be any error described herein, for example, an inconsistency in weld gap, an angular alignment error, a planar alignment error, etc.

[0149] If an undesirable gap position is detected, the method may proceed to step 1708 , whereas if an undesirable gap position is not detected, the method may skip to step 1712 .

[0150] As shown in step 1708, the method may include sending adjustment instructions to the gap adjustment mechanism. The adjustment instructions may be sent by a controller, such as a gap error controller. The adjustment instructions may include the position of a component of the system (e.g., a feed system or a bending device), the position of the material blank, the position or movement of the adjustment mechanism, etc. The gap adjustment mechanism may be any adjustment mechanism (or a combination thereof) described herein, which can adjust the components of the system described herein, including (without limitation) a feed adjustment mechanism, a drive roller adjustment mechanism, a roller steering mechanism, an outward adjustment mechanism, etc. In other words, the adjustment instructions may compensate for positioning errors. For example, the positioning error may include an inconsistency in the weld gap in the material blank, and the adjustment instructions may include an instruction to position the material blank so that a consistent weld gap is formed during welding of the material blank. The positioning error may include a planar alignment error of the material blank, and the adjustment instructions may include an instruction to position the material blank so that the edge of the material blank is substantially adjacent to the opposite edge of the material blank when connected. The positioning error may include an angular alignment error detected in the material blanks, and the adjustment instructions may include instructions to position the material blanks so that an edge of the material blanks is substantially parallel to an opposing edge of the material blanks when the material blanks are joined.

[0151] As shown in step 1710, the method may include positioning the material blank with the gap adjustment mechanism. This step may include any of the positioning components, systems, and methods described herein.

[0152] As shown in step 1712, the method may include using a connecting element to connect the material blanks. This may include, for example, using a welding machine to connect corresponding edges of the material blanks together. Connecting may include connecting the material blanks substantially continuously while the material blanks are rolling through the bending device, or after the material blanks are rolling through the bending device and rolling into the outward moving system to form a tapered structure in the outward moving system.

[0153] Fig.18 A block diagram of a control system 1800 according to an embodiment is shown. In particular, Fig.18 A machine 1802 , which may be a machine for forming a tapered structure, a computer 1804 , which may include a model 1806 , and a controller 1808 are shown. The machine 1802 may be a machine for forming a tapered structure, and the computer 1804 may include a model 1806 .

[0154] The machine 1802 may include a bending device 1810 , an adjustment mechanism 1812 , a coupling element 1814 , a feed system 1816 , an outward movement system 1818 , and at least one sensor 1820 .

[0155] The bending device 1810 can be any of those described herein, for example, a triple roller. The triple roller can have at least three rollers, including at least one bending roller and at least two guide rollers. The guide roller can include a roller row having a plurality of rollers.

[0156] Adjustment mechanism 1812 may be any device for making adjustments as described herein, and it may be suitable for adjusting any component of machine 1802, for example, a component of bending device 1810 (e.g., one or more rollers of a triple roller). In an embodiment including a triple roller, adjustment mechanism 1812 may be configured to position at least one roller, wherein the diameter of the tapered structure being formed is controlled by the relative position of the rollers. Adjustment mechanism 1812 may be configured to translate at least one roller in the triple roller relative to another roller in the triple roller without changing the angle of the roller so as to substantially continuously adjust the diameter of the tapered structure being formed. Adjustment mechanism 1812 may also include or be configured to position the angle of at least one roller relative to another roller in the triple roller. Adjustment mechanism 1812 may include a plurality of adjustment mechanisms, for example, one adjustment mechanism configured to position a corresponding roller in the triple roller. Adjustment mechanism 1822 may be configured to position the material blank so that the material blank rotates around the peak of the tapered structure or the end of the tapered structure.

[0157] The joining element 1814 can be any of those described herein, for example, a welder. The joining element 1814 can be controllable and movable.

[0158] The feed system 1816 may include its own adjustment mechanism 1822 (e.g., a feed adjustment mechanism configured to position the material blank when the material blank is fed into the bending device), or it may use the adjustment mechanism 1812 described above. The feed system 1816 may include any of the components described herein, such as a drive roller. The feed system 1816 may also include at least one edge roller 1824 configured to constrain the position of the edge of the material blank fed into or fed through the bending device 1810, wherein the adjustment mechanism 1822 is configured to position the edge roller 1824.

[0159] Outboard system 1818 may include its own adjustment mechanism 1826, or may use adjustment mechanism 1812 described above. Outboard system 1818 may include any components described herein, such as any components associated with inboard subsystem 1828 and outboard subsystem 1830.

[0160] Sensor 1820 may be any sensor described herein, and sensor 1820 may be part of machine 1802 or a separate component. Sensor 1820 may provide feedback to controller 1808, which may use the feedback to send control signals to components of machine 1802. Feedback may include geometric data of the tapered structure being formed, where the geometric data includes (without limitation) diameter, radius of curvature, taper angle, weld gap, distance of a portion of the tapered structure from the axis of the tapered structure, etc. Feedback may also or instead include force data, including (without limitation) the force required to complete an action, the action including at least one of: closing the weld gap, straightening the tapered structure to achieve tangency, adjusting the angle of one of the triple rollers, moving the rollers, and driving the material blank into or through a machine for forming the tapered structure.

[0161] Model 1806 may be any model described herein, and model 1806 may be disposed on or implemented by computer 1804. Alternatively, model 1806 may be stored on or implemented by controller 1808 or a processor associated with controller 1808. Model 1806 may send information to controller 1808, which may use the information to send control signals to components of machine 1802. Model 1806 may generally include a model for forming a tapered structure, including, without limitation, the relative positions of the rollers of a triple roller to achieve a desired tapered structure diameter, the relative positions of the material blanks as they are fed into or through the machine for forming the tapered structure, and the like.

[0162] The controller 1808 may send control signals to one or more components of the machine 1802 based on feedback from the sensor 1820 alone, information from the model 1806 alone, information from more than one sensor or model, or any combination thereof. The controller 1808 may be configured to receive feedback from the sensor 1820. The controller 1808 may also be configured to send control signals based on the feedback to any component of the system 1800, such as adjustment mechanisms 1812, 1822, 1826 for positioning components of the machine 1802 or a material blank being formed into a tapered structure.

[0163] Controller 1808 may be electrically coupled or otherwise coupled to be in communication with one or more components of system 1800. Controller 1808 may include any combination of software and / or processing circuitry suitable for controlling the various components of system 1800 described herein, including (without limitation) microprocessors, microcontrollers, application-specific integrated circuits, programmable gate arrays, and any other digital and / or analog components and combinations of the foregoing, as well as inputs and outputs for transmitting and receiving control signals, power signals, sensor signals, etc. On the one hand, this may include circuitry directly and physically associated with a component of system 1800, such as a processor. On the other hand, this may be a processor associated with a personal computer or other computing device coupled to a component of system 1800, for example, via a wired or wireless connection. Similarly, the various functions described herein may be distributed between controllers, processors, and separate computers. All such computing devices and environments are intended to fall within the meaning of the term "controller" or "processor" as used herein, unless a different meaning is explicitly provided or it is clear from the context that another meaning is understood.

[0164] Fig.19 A method 1900 for controlling the formation of a tapered structure is shown.

[0165] As shown in step 1902, method 1900 may include sensing a property with a sensor on a system for forming a tapered structure. The property may be a geometric property of the tapered structure being formed, a geometric property of the system for forming the tapered structure, a force property of the tapered structure being formed, a force property of the system for forming the tapered structure, the like, or any combination thereof. The sensor may include any sensor described herein or known to one skilled in the art.

[0166] The system for forming the tapered structure may include a bending device, which may be a triple roller, the triple roller having at least three rollers, including at least one bending roller and at least two guide rollers, wherein the guide rollers include a roller row, and the roller row has a plurality of rollers. The system for forming the tapered structure may further include an adjustment mechanism, which is configured to position at least one roller, wherein the diameter of the tapered structure being formed is controlled by the relative position of the rollers. The system for forming the tapered structure may further include a connecting element to connect the edges of the material blank together as the material blank rolls through the bending device (e.g., the triple roller) to form the tapered structure.

[0167] As shown in step 1904, method 1900 may include sending feedback from the sensor to a controller. The feedback may be based on the sensed attributes discussed above. The controller may be any controller discussed herein or other controllers known to those skilled in the art. The controller may be remote from the system or integral to the system. The feedback may be sent to the controller via a sensor signal, and the feedback may be processed / analyzed at the controller or at another location / device.

[0168] As shown in step 1906, method 1900 may include sending an adjustment instruction to an adjustment mechanism. The adjustment instruction may be sent from a controller, or from another component of the system. The adjustment instruction may be based on feedback. The adjustment mechanism may be any adjustment mechanism discussed herein, i.e., a component of a system / machine capable of adjusting the position of a material blank (including a tapered structure before, during, and after formation), and / or a component of a system / machine for forming a tapered structure.

[0169] As shown in step 1908, method 1900 may include adjusting the position of the rollers. This may include adjusting the position of at least one roller of the triple rollers, or any component of the bending apparatus, with an adjustment mechanism based on the adjustment instructions.

[0170] Fig. 20 A method 2000 for controlling the formation of a tapered structure is shown.

[0171] As shown in step 2002, method 2000 may include sensing the position of a material blank with a sensor on a system for forming a tapered structure. The material blank may be a blank for forming a tapered structure or the tapered structure itself (including the tapered structure before, during, and after forming).

[0172] The system for forming the tapered structure can be similar to that described herein, for example with reference to Fig.19 The invention may also include or instead include a feed adjustment mechanism configured to position the material blank when the material blank is fed into at least one roller, and the material blank forms a tapered structure when rolling through the bending device. The feed adjustment mechanism may include any component of the feed system (including the material blank) or any device for moving another component of the system to position the material blank when the material blank is fed into the bending device.

[0173] As shown in step 2004, method 2000 may include sending feedback from the sensor to the controller. The feedback may be based on the position of the material blank.

[0174] As shown in step 2006, method 2000 may include sending an adjustment instruction to the feed adjustment mechanism. The adjustment instruction may be sent from the controller, or from another component of the system. The adjustment instruction may be based on feedback.

[0175] As shown in step 2008, method 2000 may include adjusting the position of the material blank. This may include adjusting the position of the material blank as it is fed into or through the system to form a tapered structure based on the adjustment instructions.

[0176] Fig.21 A method 2100 for controlling the formation of a tapered structure is shown.

[0177] As shown in step 2102, method 2100 may include sensing the position of an edge of a material blank with an edge position sensor. The material blank may be a blank for forming a tapered structure or the tapered structure itself (including the tapered structure before, during, and after forming). A system for forming a tapered structure may include a rolling assembly, a connecting element, an outward movement system, and an adjustment mechanism.

[0178] As shown in step 2104, method 2100 may include sending feedback from the edge position sensor to the controller. The feedback may be based on the position of the edge of the material blank.

[0179] As shown in step 2106, method 2100 may include sending adjustment instructions to the adjustment mechanism. The adjustment instructions may be sent from the controller, or from another component of the system. The adjustment instructions may be based on feedback.

[0180] As shown in step 2108, method 2100 may include adjusting the position of the tapered structure (e.g., before, during, or after forming). This may include using an adjustment mechanism to adjust the position of the tapered structure relative to the rolling assembly based on an adjustment instruction, such as after the material blank has passed through the rolling assembly.

[0181] Fig. 22 A method 2200 for forming a tapered structure is shown.

[0182] As shown in step 2202, method 2200 may include sensing sensor data with a sensor. The sensor data may include at least one of the following: geometric properties of the tapered structure being formed, geometric properties of the machine component, force properties of the tapered structure being formed, force properties of the machine component, position of the material blank, machine component position, inconsistency of weld gap in the material blank, planar alignment error in the material blank, and angular alignment error of the material blank. Sensing may be performed at any step during the method 2200 shown, and adjustments may be made at any step based on the sensor data.

[0183] As shown in step 2204, method 2200 may include sending feedback from the sensor to the controller. The feedback may be based on the sensor data.

[0184] As shown in step 2206, method 2200 may include sending an adjustment instruction to the adjustment mechanism. The adjustment instruction may be sent from the controller, or from another component of the system. The adjustment instruction may be based on feedback.

[0185] As shown in step 2208, method 2200 may include adjusting the position of the material blank based on the adjustment instruction using the adjustment mechanism. Adjusting the position of the material blank may include the adjustment mechanism positioning at least one of: the feed system, the at least three rollers, the outward movement system, and the tapered structure being formed.

[0186] As shown in step 2210, method 2200 can include driving the material blank with a feed system. The feed system can be any feed system described herein.

[0187] As shown in step 2212, method 2200 may include feeding the material blank through a rolling assembly. The rolling assembly may be any of those described herein, for example, a triple roller, which includes at least three rollers having at least one curved roller and at least two guide rollers. The guide roller may include a roller row having a plurality of rollers.

[0188] As shown in step 2214, method 2200 can include joining edges of the material blank together to form a tapered structure as the material blank is rolled through the rolling assembly. The joining can utilize the joining elements described herein.

[0189] As shown in step 2216, method 2200 can include directing the material blank out of the rolling assembly using an outward movement system. The outward movement system can be any outward movement system described herein.

[0190] The control systems described herein include control systems involving the entire build system or a portion thereof, including (without limitation) the feed system, the bending device, the connecting elements, and the outward movement system. As used in this disclosure, "control system" shall mean a control system for any and all of the aforementioned systems or combinations thereof, unless a specific component / machine is clearly required or otherwise is clear from the context.

[0191] In the foregoing, the terms "machine" and "component" refer to the elements or combinations of elements of the construction system described above, unless otherwise stated herein or clearly understood from the context. These terms can also generally refer to the construction system.

[0192] The above control systems, devices, methods, processes, etc. may be implemented in hardware, software, or any combination thereof suitable for controlling, acquiring data, and processing data as described herein. This includes implementation in one or more microprocessors, microcontrollers, embedded microcontrollers, programmable digital signal processors, or other programmable devices or processing circuits, and internal and / or external memory. This may also include or instead include one or more application-specific integrated circuits, programmable gate arrays, programmable array logic components, or any other device or device that may be configured to process electronic signals. It will be further understood that the implementation of the process or device described above may include computer executable code established using a structured programming language (such as C), an object-oriented programming language (such as C++), or any other high-level or low-level programming language (including assembly language, hardware description language, and database programming language and technology), which may be stored, compiled, or interpreted to run on one of the above devices and different combinations of processors, processor architectures, or different combinations of hardware and software. At the same time, processing may be distributed on devices, such as the various systems described above, or all functionality may be incorporated into dedicated standalone devices. All such permutations and combinations are intended to fall within the scope of the present disclosure.

[0193] Embodiments disclosed herein may include a computer program product including computer executable or computer usable code that, when executed on one or more computing devices, performs any and / or all of the steps of the control system described above. The code may be stored in a non-transitory manner in a computer memory, which may be a memory from which the program is executed (such as a random access memory associated with a processor), or a storage device such as a disk drive, flash memory, or any other optical, electromagnetic, magnetic, infrared or other device or combination of devices. On the other hand, any of the control systems described above may be embodied in any suitable transmission or propagation medium carrying computer executable code and / or any input or output thereof.

[0194] It will be understood that the methods and systems described above are set forth by way of example and not limitation. Many variations, additions, omissions, and other modifications will be apparent to those of ordinary skill in the art. In addition, the order or presentation of the method steps in the above description and figures is not intended to require that the method perform the recited steps in this order, unless a specific order is clearly required or is clearly understood from the context.

[0195] The meaning of the method steps of the invention(s) described herein is intended to include any suitable means for causing one or more other groups or entities to perform the steps consistent with patentability of the appended claims, unless a different meaning is clearly provided or a different meaning is clearly understood from the context. Such groups or entities need not be directed or controlled by any other group or entity and need not be subject to a particular jurisdiction.

[0196] Systems, methods and apparatus for building tapered structures and control systems and methods thereof are described herein. It will be understood that while the exemplary embodiments herein emphasize the building of tapered structures and their control, the principles of the present invention may be adapted to other manufacturing processes. All such variations that may be adapted to use the systems, methods and apparatus described herein are intended to fall within the scope of the present disclosure.

[0197] Other components of the control system may also be included, such as input devices, including keyboards, touch pads, mice, switches, dials, buttons, etc., and output devices, such as displays, speakers or other audio frequency converters, light emitting diodes, etc. Other hardware may also include or be modified to include a variety of cable connections and / or hardware adapters to connect to, for example, external computers, external hardware, external instruments or data acquisition systems, etc.

[0198] The control system may include a network interface, or be connected to a communication relationship with the network interface. The network interface may include any combination of hardware and software suitable for connecting the control system and the construction system to a remote computer in a communication relationship through a data network. By way of example and not limitation, this may include electronic devices for wired or wireless Ethernet connections running according to the IEEE 802.11 standard (or any variation thereof), or any other small or large-scale wireless network components, etc. This may include hardware for small-scale data communications, such as Bluetooth or infrared transceivers, which can be used to connect to a local area network, etc., which in turn connects to a data network such as the Internet. This may also include or instead include hardware / software for WiMax connections or cellular network connections (using, for example, CDMA, GSM, LTE or any other appropriate protocol or combination of protocols). Consistently, the control system may be configured to control the participation of the construction system in any network connected to the network interface.

[0199] In the foregoing, various tasks involving the relative motion of various components have been described. But it is recognized that different design constraints or other practical considerations may require certain components to remain fixed (relative to the ground) or only experience minimal motion. For example, the construction system may be designed so that any one or more of the following components remain fixed relative to the ground: any desired component of the blank material source, the feed system, any desired component of the bending device, any desired component of the welding machine, any desired component of the outward movement system, the peak / top / end of the tapered structure being built, etc. Similarly, the system may be designed so that the above components do not remain fixed relative to the ground (or, in addition to the above mentioned, relative to each other). In some embodiments, the heaviest and most difficult to move components remain fixed relative to the ground. In some embodiments, the relative motion of the components is selected to best reduce the risk of damaging things near the system. In some embodiments, the relative motion of the components is selected to maximize the expected life of the system or the expected life of one or more components in general.

[0200] While particular embodiments have been shown and described, it will be apparent to those skilled in the art that various changes and modifications in form and details may be made without departing from the spirit and scope of the present disclosure, which is intended to form a part of the present invention as defined by the claims, which are to be construed in the broadest sense permitted by law.

Claims

1. A control system for forming a tapered structure, comprising: at least three rollers, including at least one bending roller and at least two guide rollers, the at least two guide rollers including a roller row including a plurality of rollers; a roller adjustment mechanism configured to change an angle of the plurality of rollers relative to the material blank to change a first position of the material blank when the material blank is fed into the at least three rollers; a feed adjustment mechanism configured to adjust a second position of the material blank when the material blank is fed into the at least three rollers, the material blank forming the tapered structure when it rolls over the at least three rollers; as well as a joining element configured to join together edges of the material blank as the material blank is rolled over the at least three rollers to form the tapered structure; a model implemented on a computer, the model comprising a series of positions and feed angles of the material blank as the material blank is fed into or through the at least three rollers to form the tapered structure; a sensor configured to detect a position of the material blank; as well as A controller configured to receive instructions based on the series of positions and feed angles of the model, and to receive the position of the material blank from the sensor, the controller further configured to send a first control signal to the roller adjustment mechanism to turn the plurality of rollers to change the first position of the material blank, and selectively send a second control signal to the feed adjustment mechanism to adjust the second position of the material blank, wherein each of the first control signal and the second control signal is based on a combination of instructions based on the series of positions and feed angles of the model and the position of the material blank detected by the sensor.

2. The control system according to claim 1, characterized in that: The sensor comprises an edge position sensor, and wherein the sensor is configured to detect the position of an edge of the material blank.

3. The control system according to claim 1, characterized in that: The sensor includes one or more of an optical sensor, a contact sensor, an electromagnetic sensor, a force sensor and an imaging device.

4. The control system according to claim 1, characterized in that: The model includes a series of positions of the material blank calculated before the material blank is fed into or fed through the at least three rollers to form the tapered structure.

5. The control system according to claim 1, characterized in that: The model includes the relative positions of one or more of the at least three rolls.

6. The control system according to claim 1, characterized in that: The model includes edge locations of the material blank.

7. The control system according to claim 1, characterized in that: The first control signal to the roller adjustment mechanism is a continuous control signal used to steer the plurality of rollers to position the material blank as it is fed into or through the at least three rollers to form the tapered structure.

8. The control system according to claim 1, characterized in that: The model of the series of positions and feed angles of the material blank as it is fed into or through the at least three rollers to form the tapered structure includes rotational movement of the material blank about the peak of a flat-topped cone.

9. A control system for forming a tapered structure, comprising: An edge position sensor configured to provide feedback including the position of an edge of a material blank to be formed into a tapered structure in a machine for forming the tapered structure, the machine comprising: at least three rollers, including at least one bending roller and at least two guide rollers, the at least two guide rollers including a roller row including a plurality of rollers; a feed adjustment mechanism configured to position the material blank when the material blank is fed into the at least three rollers, the material blank forming the tapered structure when it rolls over the at least three rollers; a roller adjustment mechanism configured to position the angle of rollers on the roller row of at least one of the at least two guide rollers; and a joining element configured to join together edges of the material blank as the material blank is rolled over the at least three rollers to form the tapered structure; and A controller is configured to receive feedback from the edge position sensor, the feedback including the position of the edge of the material blank, and based on the feedback, send control signals to the feed adjustment mechanism and to the roller adjustment mechanism to position the material blank as the material blank is fed into the machine or fed through the machine to form the tapered structure.

10. The control system according to claim 9, characterized in that: The control signal adjusts the roller adjustment mechanism to adjust the position angle of the rollers on the roller row.

11. The control system according to claim 9, characterized in that: Also included are edge rollers configured to constrain the position of edges of the material blank, wherein a control signal to the feed regulation mechanism regulates the edge rollers.

12. The control system according to claim 9, characterized in that: The controller is further configured to receive instructions from a model of an ideal edge position of the material blank, and the control signals to the feed adjustment mechanism and the roller adjustment mechanism are further based on the ideal edge position of the material blank.

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