A molding device and a molding process

Abstract

This invention discloses a forming apparatus and forming process. The apparatus consists of a tube blank, a tube feeder, a heating assembly, an external thread forming assembly, and a machine vision assembly. The coiled tube blank enters the online heat treatment and external thread forming process under the action of the tube feeder. Along the direction of tube blank movement, the apparatus consists of the tube feeder, the heating assembly, the external thread forming assembly, and the machine vision assembly in sequence. This invention integrates the online annealing process and the external thread forming process of the external threaded tube into the same process, reducing the number of uncoiling and recoiling operations of the tube blank and improving the production efficiency of the external threaded tube. Secondly, this invention utilizes online heat treatment to improve the plasticity of the rolled layer of the tube blank, reducing the deformation resistance of the tube blank during external thread rolling and improving the forming quality of the external thread. Furthermore, this invention employs machine vision technology to assist in the rolling of the external thread, forming a negative feedback adjustment system for external thread quality control, reducing the impact of tube blank surface fluctuations on the external thread forming process and improving the stability of the external thread forming process.

Description

Technical Field

[0001] This invention relates to the field of externally threaded pipes, and more specifically to a forming device and forming process. Background Technology

[0002] Externally threaded tubes, also known as externally ribbed tubes or externally finned tubes, rely on the threaded teeth (also known as ribs or fins) on the outer wall of the tube to expand the heat transfer area, which greatly improves the heat transfer coefficient of the condenser tube. At the same time, due to the surface tension, the threaded teeth can increase the turbulence of the fluid outside the tube, thus having a better enhancing effect on the condensation outside the tube.

[0003] Compared to traditional plain tubes, using externally threaded tubes in condensers offers advantages. The externally threaded tubes have a larger heat exchange area and a higher heat transfer coefficient, allowing for a reduction in the number of condenser tubes and thus significantly reducing the condenser's size and weight, achieving energy savings and cost reduction. However, for the same specifications of externally threaded tubes, the forming quality of the thread teeth (including thread depth and tooth profile fullness) directly determines the heat transfer performance of the condenser tube; that is, the better the quality of the thread teeth, the higher the heat transfer performance of the condenser tube. Common manufacturing methods for externally threaded condenser tubes include the plowing method and the drawing method (or rolling method). The plowing method struggles to guarantee the stability of the thread tooth forming, while the drawing method offers higher stability and production efficiency.

[0004] In summary, this invention provides a forming device and forming process based on rolling to further improve the forming quality of threaded teeth, thereby improving the heat exchange effect and service life of external threaded tubes. Summary of the Invention

[0005] The main objective of this invention is to overcome at least one of the defects of the prior art and provide a forming device and forming process to improve the forming quality of the thread and ensure the heat exchange performance of the external threaded tube.

[0006] The objective of this invention is achieved through the following technical solution: a forming device, which mainly includes a tube blank, a tube feeder, a heating component, an external thread forming component, and a machine vision component. The tube blank, after being coiled, enters the online heat treatment and external thread forming process under the action of the tube feeder. Along the movement direction of the tube blank, the device consists of the tube feeder, the heating component, the external thread forming component, and the machine vision component in sequence.

[0007] Preferably, the heating assembly includes a first sensor, a second sensor, and a third sensor, and along the direction of movement of the tube blank, the heating assembly consists of the first sensor, the second sensor, and the third sensor in sequence.

[0008] Preferably, the first sensor, the second sensor, and the third sensor have the same structure, each consisting of a transformer, a first servo motor, a first gear, a compensation bar, a moving platform, a water inlet pipe, a water outlet pipe, and a coil. The transformer is installed on the top of the moving platform, the first servo motor is installed on the top side of the moving platform, the first gear is installed at the end of the output shaft of the first servo motor, the compensation bar is installed on the bottom side of the moving platform, the coil is installed on the transformer terminal block, and the coil is equipped with the water inlet pipe and the water outlet pipe.

[0009] Preferably, the first sensor, the second sensor, and the third sensor are slidably mounted on a slide rail in sequence, and a rack is provided on the side of the slide rail, the rack meshing with the first gear on the first sensor, the first gear on the second sensor, and the first gear on the third sensor.

[0010] Preferably, the external thread forming assembly is a three-roll mill, that is, the three rolls envelop the die to form a die, each roll envelops 120°, and the reduction or rolling force of the three rolls is the same.

[0011] Preferably, the surface of the roll of the external thread forming assembly is provided with protrusions and grooves that engage with the external thread of the tube blank.

[0012] Preferably, the machine vision component comprises a base, an end cap, a second gear, a drive shaft, a gear ring, a laser sensor, an inner ring, a synchronous belt, a synchronous pulley, and a second servo motor. The base is fixed to the foundation. The inner ring is rotatably disposed between the base and the end cap. Three mounting seats are arranged in a circumferential array on the side end of the inner ring. Each mounting seat is equipped with a laser sensor. The gear ring is disposed inside the inner ring. Three second gears are meshed in a circumferential array inside the gear ring. Each second gear is connected to the synchronous pulley through the drive shaft penetrating the base. The three synchronous pulleys are driven by the synchronous belt. One of the synchronous pulleys is connected to the output shaft of the second servo motor. The housing of the second servo motor is fixed to the side end face of the base.

[0013] Preferably, the initial monitoring position of the three laser sensors is at the junction of the three rollers, and the inner ring performs a 120° reciprocating motion under the drive of the second servo motor.

[0014] Preferably, the monitoring range of the laser sensor is 3 to 5 pitches, and the installation angle of the laser sensor is determined by the helix angle of the external thread, so that the monitoring line of the laser sensor is perpendicular to the helix.

[0015] Preferably, the tube blank is made of non-ferrous metal and the external thread helix angle is 0° to 90°.

[0016] The present invention also provides a molding process, comprising the following steps:

[0017] S1. Design the external thread parameters reasonably according to the blank size to ensure that the heat exchange performance of the finished condenser tube meets the production requirements.

[0018] S2. Determine the maximum or ultimate rolling force F that the billet can withstand under conventional rolling based on the external thread parameters. max And determine the range of electrical parameters of the heating components according to the heat treatment requirements;

[0019] S3. The tube blank is drawn to the set size by a coiling machine and then sent to the induction heating area by a tube feeder to start the first sensor.

[0020] S4. Start the machine vision component, set the speed of the second servo motor according to the linear velocity of the tube blank, and monitor the thread depth and tooth profile fullness at each point of the external thread.

[0021] S5. Start the external thread forming assembly and gradually increase the rolling force F of the rolls to roll the external thread of the tube blank:

[0022] S51, If ​​the rolling force F is increased to 80% of F max Previously, when the external thread depth reached the set value h, the rolling force F was kept constant and the process proceeded to step S7.

[0023] S52, If the rolling force F is increased to 80% of F max If the external thread depth has not yet reached the set value h, the second sensor is activated, and the rolling force F is further increased to F0. max Proceed to step S6;

[0024] S6. Activate the second sensor, increasing the rolling force F to F0. max :

[0025] S61. If the external thread depth reaches the set value h, then reduce the rolling force F of the rolls to 80% F. max And by increasing the current value of the second sensor, the external thread depth reaches the set value h, then proceed to step S7;

[0026] S62. If the external thread depth still does not reach the set value h, then maintain the rolling force of the rolls at F. max The third sensor is activated. After increasing the current value of the third sensor to achieve the set thread depth h, the rolling force F of the rolls is reduced to 80% F. max And continue to increase the current value of the third sensor to make the external thread depth reach the set value h, then proceed to step S7;

[0027] S7. Adjust the process parameters and continue rolling the external thread of the tube blank.

[0028] Preferably, in steps S5 and S6, when the external thread depth does not reach the set value h, the production parameters and time point are marked, and the location of the defective external thread of the tube blank is recorded.

[0029] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0030] 1. This invention integrates the online annealing and external thread forming processes of the external threaded pipe forming process into the same step, reducing the number of uncoiling and recoiling operations, simplifying the forming process, thereby improving production efficiency and reducing production costs.

[0031] 2. This invention utilizes the skin effect of induced current to heat the rolled layer of the external threaded tube through a heating component, thereby reducing the deformation resistance and work hardening degree of the rolled layer, avoiding the generation of rolling cracks, and thus improving the forming quality of the thread teeth.

[0032] 3. This invention uses machine vision to monitor the forming quality of the thread teeth, and continuously adjusts the electrical parameters of the sensor and the rolling force of the rolls based on the feedback data of the machine vision, forming a negative feedback adjustment system to ensure the forming quality of the thread teeth, reduce production energy consumption, and ensure the stability of the thread tooth forming process. Attached Figure Description

[0033] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:

[0034] Figure 1 This is a flowchart of the molding process of the present invention;

[0035] Figure 2 This is a first view of the molding apparatus of the present invention;

[0036] Figure 3 This is a second view of the molding apparatus of the present invention;

[0037] Figure 4 This is a structural diagram of the heating component in the molding apparatus of the present invention;

[0038] Figure 5 This is a structural diagram of a single-stage inductor in the heating component of the molding apparatus of the present invention;

[0039] Figure 6 This is a first view of the machine vision component in the molding apparatus of the present invention;

[0040] Figure 7 This is a second view of the machine vision component in the molding apparatus of the present invention;

[0041] Labels in the diagram: 1. Tube blank; 2. Tube feeder; 3. Heating assembly; 31. First sensor; 32. Second sensor; 33. Third sensor; 301. Rack; 302. Slide rail; 303. Transformer; 304. First servo motor; 305. First gear; 306. Compensating bar; 307. Moving platform; 308. Inlet pipe; 309. Outlet pipe; 310. Coil; 4. External thread forming assembly; 5. Machine vision assembly; 501. Base; 502. End cap; 503. Second gear; 504. Drive shaft; 505. Gear ring; 506. Laser sensor; 507. Inner ring; 508. Synchronous belt; 509. Synchronous pulley; 510. Second servo motor. Detailed Implementation

[0042] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0043] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "front," "rear," "vertical," "horizontal," "inner," and "outer," which indicate directional or positional relationships, are based on the directional or positional relationships shown in the accompanying drawings. These are merely for ease of description and do not indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation; therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0044] A molding device, such as Figure 2 and Figure 3 As shown, it mainly includes a tube blank 1, a tube feeder 2, a heating assembly 3, an external thread forming assembly 4, and a machine vision assembly 5. After being coiled, the tube blank 1 enters the online heat treatment and external thread forming process under the action of the tube feeder 2. Along the movement direction of the tube blank 1, the device consists of the tube feeder 2, the heating assembly 3, the external thread forming assembly 4, and the machine vision assembly 5 in sequence.

[0045] like Figure 4 As shown, the heating assembly 3 includes a first sensor 31, a second sensor 32 and a third sensor 33. Along the movement direction of the tube blank 1, the heating assembly 3 consists of the first sensor 31, the second sensor 32 and the third sensor 33 in sequence.

[0046] The first sensor 31, the second sensor 32 and the third sensor 33 are slidably mounted on the slide rail 302 in sequence. The slide rail 302 is provided with a rack 301 on its side. The rack 301 meshes with the first gear 305 on the first sensor 31, the first gear 305 on the second sensor 32 and the first gear 305 on the third sensor 33.

[0047] The first sensor 31, the second sensor 32, and the third sensor 33 have the same structure, such as Figure 5 As shown, the system comprises a transformer 303, a first servo motor 304, a first gear 305, a compensating strip 306, a moving platform 307, an inlet pipe 308, an outlet pipe 309, and a coil 310. The transformer 303 is mounted on the top of the moving platform 307. The first servo motor 304 is mounted on the top side of the moving platform 307. The first gear 305 is mounted on the end of the output shaft of the first servo motor 304. The compensating strip 306 is mounted on one side of the bottom of the moving platform 307. The coil 310 is mounted on the terminal block of the transformer 303 and has an inlet pipe 308 and an outlet pipe 309.

[0048] like Figure 6 and Figure 7 As shown, the machine vision component 5 consists of a base 501, an end cap 502, a second gear 503, a drive shaft 504, a gear ring 505, a laser sensor 506, an inner ring 507, a synchronous belt 508, a synchronous pulley 509, and a second servo motor 510. The base 501 is fixed on the foundation. An inner ring 507 is rotatably disposed between the base 501 and the end cap 502. Three mounting seats are arranged in a circumferential array on the side end of the inner ring 507. Each mounting seat is equipped with a laser sensor 506. A gear ring 505 is disposed inside the inner ring 507. Three second gears 503 are meshed in a circumferential array inside the gear ring 505. Each second gear 503 is connected to a synchronous pulley 509 through a drive shaft 504 that penetrates the base 501. The three synchronous pulleys 509 are driven by a synchronous belt 508. One of the synchronous pulleys 509 is connected to the output shaft of the second servo motor 510. The housing of the second servo motor 510 is fixed on the side end face of the base 501.

[0049] Specifically, the tube blank 1 is made of T2 copper tube, with an outer diameter of 50mm, a wall thickness of 8mm, an external thread helix angle of 0°, a pitch of 7mm, a tooth width of 3mm, a thread depth of 4mm, and an ultimate rolling force F. max It is 30kN.

[0050] Specifically, the external thread forming component 4 is a three-roll pass mill, that is, the three rolls envelop the pass to form a pass, each roll enveloping 120°, and the reduction or rolling force of the three rolls is the same.

[0051] More specifically, the roll surface of the external thread forming assembly 4 is provided with protrusions and grooves that engage with the external thread of the tube blank 1.

[0052] Furthermore, the initial monitoring position of the three laser sensors 506 is the junction of the three rolls, and the inner ring 507 performs a 120° reciprocating motion under the drive of the second servo motor 510.

[0053] Furthermore, the monitoring range of the laser sensor 506 is 4 pitches, and the installation angle of the laser sensor 506 is determined by the helix angle of the external thread, ensuring that the monitoring line of the laser sensor 506 is perpendicular to the helix.

[0054] In a preferred embodiment of the present invention, a molding process, such as Figure 1 As shown, it includes the following steps:

[0055] S1. Design the external thread parameters reasonably according to the blank size to ensure that the heat exchange performance of the finished condenser tube meets the production requirements.

[0056] S2. Determine the maximum or ultimate rolling force F that the billet can withstand under conventional rolling based on the external thread parameters. max The value is 30kN, and the range of electrical parameters of the heating component is determined according to the heat treatment requirements;

[0057] S3. The tube blank is drawn to the set size by a coiling machine and then sent to the induction heating area by a tube feeder to start the first sensor.

[0058] S4. Start the machine vision component, set the speed of the second servo motor according to the linear velocity of the tube blank, and monitor the thread depth and tooth profile fullness at each point of the external thread through 3D laser triangulation measurement technology.

[0059] S5. Start the external thread forming assembly and gradually increase the rolling force F of the rolls to roll the external thread of the tube blank:

[0060] S51. If the external thread depth reaches 4mm before the rolling force F is increased to 24kN, then keep the rolling force F unchanged and proceed to step S7.

[0061] S52. If the external thread depth has not reached 4mm after the rolling force F is increased to 24kN, the second sensor is activated and the rolling force F is increased to 30kN. Proceed to step S6.

[0062] S6. Activate the second sensor, increasing the rolling force F of the rolls to 30kN:

[0063] S61. If the external thread depth reaches 4mm, reduce the rolling force F of the roll to 24kN, and increase the current value of the second sensor to make the external thread depth reach 4mm, then proceed to step S7.

[0064] S62. If the external thread depth still does not reach 4mm, keep the rolling force of the roll at 30kN, start the third sensor, increase the current value of the third sensor to make the external thread depth reach 4mm, reduce the rolling force F of the roll to 24kN, and continue to increase the current value of the third sensor to make the external thread depth reach 4mm, then go to step S7.

[0065] S7. Adjust the process parameters and continue rolling the external thread of the tube blank.

[0066] More specifically, in steps S5 and S6, when the external thread depth does not reach 4mm, the production parameters and time points are marked, and the location of the defective external thread of the tube blank 1 is recorded.

[0067] Specific examples have been used to illustrate the principles and implementation methods of this invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of this invention. Furthermore, those skilled in the art will recognize that, based on the ideas of this invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this invention.

Claims

1. A molding process, characterized in that, The forming device is used for forming. The forming device includes a tube blank (1), a tube feeder (2), a heating component (3), an external thread forming component (4), and a machine vision component (5). The tube blank (1) after being coiled is subjected to online heat treatment and external thread forming process under the action of the tube feeder (2). Along the movement direction of the tube blank (1), the forming device consists of the tube feeder (2), the heating component (3), the external thread forming component (4), and the machine vision component (5) in sequence. The heating assembly (3) includes a first sensor (31), a second sensor (32) and a third sensor (33). Along the movement direction of the tube blank (1), the heating assembly (3) consists of the first sensor (31), the second sensor (32) and the third sensor (33) in sequence. The first sensor (31), the second sensor (32), and the third sensor (33) have the same structure, each consisting of a transformer (303), a first servo motor (304), a first gear (305), a compensation bar (306), a moving platform (307), a water inlet pipe (308), a water outlet pipe (309), and a coil (310). The transformer (303) is installed on the top of the moving platform (307). The first servo motor (304) is installed on the top side of the moving platform (307). The first gear (305) is installed at the end of the output shaft of the first servo motor (304). The compensation bar (306) is installed on one side of the bottom of the moving platform (307). The coil (310) is installed on the terminal block of the transformer (303). The coil (310) is equipped with the water inlet pipe (308) and the water outlet pipe (309). The external thread forming assembly (4) is a three-roll die rolling mill, that is, the three rolls envelop the die, each roll envelops 120°, and the reduction or rolling force of the three rolls is the same; The machine vision component (5) consists of a base (501), an end cap (502), a second gear (503), a drive shaft (504), a gear ring (505), a laser sensor (506), an inner ring (507), a synchronous belt (508), a synchronous pulley (509), and a second servo motor (510). The base (501) is fixed on the foundation. The inner ring (507) is rotatably disposed between the base (501) and the end cap (502). The inner ring (507) has three mounting seats arranged in a circumferential array on its side end. Each mounting seat is equipped with a laser sensor (506). 06), the inner ring (507) is provided with the gear ring (505), and the gear ring (505) is circumferentially arrayed with three second gears (503). Each second gear (503) is connected to the synchronous pulley (509) through the transmission shaft (504) that penetrates the base (501). The three synchronous pulleys (509) are driven by the synchronous belt (508). One of the synchronous pulleys (509) is connected to the output shaft of the second servo motor (510). The housing of the second servo motor (510) is fixed on the side end face of the base (501). The molding process includes the following steps: S1. Design the external thread parameters reasonably according to the blank size to ensure that the heat exchange performance of the finished condenser tube meets the production requirements; S2. Determine the maximum or ultimate rolling force F that the billet can withstand under conventional rolling based on the external thread parameters. max And determine the range of electrical parameters of the heating components according to the heat treatment requirements; S3. The tube blank is drawn to the set size by a coiling machine, and then the coiled tube blank is sent to the induction heating area by a tube feeder to start the first sensor; S4. Activate the machine vision component, set the speed of the second servo motor according to the linear velocity of the tube blank, and monitor the thread depth and tooth profile fullness at each point of the external thread in real time; S5. Start the external thread forming assembly and gradually increase the rolling force F of the rolls to roll the external thread of the tube blank; S51. If the rolling force F is increased to 80% of F max Previously, if the external thread depth reached the set value h, the rolling force F was kept constant and the process proceeded to step S7. S52. If the rolling force F is increased to 80% of F max If the external thread depth has not yet reached the set value h, then based on the monitoring data from the machine vision component, the second sensor is activated, and the rolling force F is further increased to F0. max Proceed to step S6; S6. Activate the second sensor, increasing the rolling force F to F0. max ; S61. If the external thread depth reaches the set value h, reduce the rolling force F of the rolls to 80% F. max And by increasing the current value of the second sensor, the external thread depth reaches the set value h, then proceed to step S7; S62. If the external thread depth still does not reach the set value h, then maintain the rolling force of the rolls at F. max The third sensor is activated. After increasing the current value of the third sensor to achieve the set thread depth h, the rolling force F of the rolls is reduced to 80% of F. max And continue to increase the current value of the third sensor to make the external thread depth reach the set value h, then proceed to step S7; S7. Based on the continuous monitoring data from the machine vision component, adjust the process parameters and continue rolling the external thread of the tube blank.

2. The molding process according to claim 1, characterized in that, The first sensor (31), the second sensor (32) and the third sensor (33) are slidably mounted on the slide rail (302) in sequence. The slide rail (302) has a rack (301) on its side. The rack (301) meshes with the first gear (305) on the first sensor (31), the first gear (305) on the second sensor (32) and the first gear (305) on the third sensor (33).

3. The molding process according to claim 1, characterized in that, The surface of the roll of the external thread forming assembly (4) is provided with protrusions and grooves that engage with the external thread of the tube blank (1).

4. The molding process according to claim 1, characterized in that, The initial monitoring position of the three laser sensors (506) is the junction of the three rollers, and the inner ring (507) is reciprocating by rotating 120° under the drive of the second servo motor (510).

5. The molding process according to claim 1, characterized in that, The monitoring range of the laser sensor (506) is 3 to 5 pitches, and the installation angle of the laser sensor (506) is determined by the helix angle of the external thread, so that the monitoring line of the laser sensor (506) is perpendicular to the helix.

6. The molding process according to claim 1, characterized in that, The tube blank (1) is made of non-ferrous metal and the external thread helix angle is 0°~90°.

7. The molding process according to claim 1, characterized in that, In steps S5 and S6, when the external thread depth does not reach the set value h, the production parameters and time point are marked, and the location of the defective external thread on the tube blank is recorded.

Images