A mandrel bow calibration system and method

Abstract

The application relates to a mandrel bow straightening system and method, which comprises a straightening device, an intelligent robot and a central control device, the straightening device comprises a straightening lathe, a blowtorch movably arranged on the straightening lathe and a straightening support; the central control device is connected with the intelligent robot, the blowtorch and the straightening support, and is used for determining a cutting position on a mother mandrel according to selected, input or received outer diameters and lengths of completed extended mother mandrels and next process requirements; controlling the intelligent robot to cut a mandrel from the mother mandrel, measuring a length, an outer diameter and a bow of the mandrel, forming a bow distribution curve in the length direction of the mandrel, marking an out-of-gauge point position and an out-of-gauge value, and transferring the mandrel to the straightening device; and controlling the straightening device to perform straightening treatment on the out-of-gauge point, so that the mandrel with an unqualified bow can be automatically calibrated, the influence of human factors on the process is excluded, and the production efficiency is improved.

Description

Technical Field

[0001] This application relates to the field of optical fiber preform preparation technology, and in particular to a core rod curvature calibration system and method. Background Technology

[0002] In the manufacturing process of optical fiber preforms, before the mother rod produced in the VAD process is transferred to the OVD process for use, it must be stretched and straightened.

[0003] The common method for straightening extended core rods is to observe and measure with a ruler or dial indicator, and then manually straighten them. However, this method is difficult to eliminate the influence of human factors on the process, and the production efficiency is relatively low due to human factors. It also cannot guarantee that the entire length is straightened, and cannot fundamentally solve the technical problem of subsequent optical fiber preform core package concentricity scrapping caused by large core rod curvature. Summary of the Invention

[0004] This application provides a mandrel curvature calibration system and method, which can automatically calibrate mandrels with substandard curvature, eliminate the influence of human factors on the process, and improve production efficiency.

[0005] Firstly, a mandrel bow curvature calibration system is provided, comprising:

[0006] A bar straightening device, comprising a bar straightening lathe, a blowtorch movably mounted on the bar straightening lathe, and a bar straightening bracket;

[0007] Intelligent robots;

[0008] The system includes a central control device connected to the intelligent robot, the blowtorch, and the alignment rod support. The central control device is used to: determine the cutting position on the mother rod based on the selected, input, or received outer diameter and length of the completed extension of the mother rod, and the requirements of the next process; control the intelligent robot to cut a mandrel from the mother rod, measure the mandrel's length, outer diameter, and curvature to form a curvature distribution curve along the mandrel's length, and mark the locations and values ​​of any points exceeding the standard; and transfer the mandrel to the alignment rod device; and control the alignment rod device to straighten the points exceeding the standard.

[0009] In some embodiments, the system further includes a storage unit;

[0010] The central control device is also connected to the storage unit and is used to: store the length and outer diameter of the mandrel before straightening, the curvature distribution curve before and after straightening, and the mandrel straightening process parameters for each operation of the mandrel straightening device into the storage unit. The mandrel straightening process parameters include the hydrogen-oxygen flame flow rate of the blowtorch, the burning time, the blowtorch position, the height of the mandrel straightening support, and the position of the mandrel straightening support.

[0011] The central control device is also used for:

[0012] The historical data of the storage unit over a period of time is retrieved, and the bow curvature distribution curves of the mandrel before and after straightening are analyzed in the historical data to obtain the bow curvature change.

[0013] Based on the changes in the length, outer diameter, and curvature of the mandrel before straightening in the historical data, the mandrel straightening process parameters of the mandrel straightening device are adjusted.

[0014] In some embodiments, the system further includes a storage unit;

[0015] The central control device is also connected to the storage unit and the extension tower, and is used for:

[0016] Based on the curvature distribution curve of the mandrel before straightening, the curvature distribution curve of the extended mother rod is formed.

[0017] The curvature distribution curve of the extended mother rod and the extension process parameters for each start-up of the extension tower are stored in the storage unit. The extension process parameters include extension speed, hydrogen and oxygen gas flow rate, and furnace temperature.

[0018] The central control device is also used for:

[0019] The historical data of the storage unit over a period of time is retrieved, and the bow curvature distribution curve of the extended mother rod in the historical data is analyzed to obtain the bow curvature change.

[0020] Based on the changes in the curvature, the extended process parameters in the historical data are analyzed to identify anomalies and correct them.

[0021] In some embodiments, the central control device is also used to: after the calibration device has straightened all the out-of-standard points, control the intelligent robot to remove the mandrel from the calibration device and measure the curvature of the mandrel again to confirm that it is qualified; if it is not qualified, mark the location and value of the out-of-standard point and send it back to the calibration device.

[0022] In some embodiments, the central control device is further configured to: when the mandrel is confirmed to be qualified after multiple straightening operations, merge the mandrel straightening process parameters from the multiple operations of the mandrel straightening device to obtain updated mandrel straightening process parameters.

[0023] The calibration rod process parameters include the hydrogen-oxygen flame flow rate of the blowtorch, the burning time, the blowtorch position, the height of the calibration rod support, and the position of the calibration rod support.

[0024] Secondly, a method for calibrating the curvature of a mandrel is provided, which includes the following steps:

[0025] Based on the outer diameter and length of the extended mother rod, and the requirements of the next process, the cutting position is determined on the mother rod.

[0026] Cut a mandrel from the mother rod, measure the length, outer diameter and curvature of the mandrel to form a curvature distribution curve along the length of the mandrel, and mark the locations and values ​​of the points exceeding the standard.

[0027] The points that exceed the standard should be straightened.

[0028] In some embodiments, the method further includes adjusting the calibration bar process parameters, specifically including:

[0029] Retrieve historical data for a period of time. The historical data includes: the length and outer diameter of the mandrel before straightening, the curvature distribution curve before and after straightening, and the mandrel straightening process parameters for each operation of the mandrel straightening device. The mandrel straightening process parameters include the hydrogen-oxygen flame flow rate of the blowtorch, the burning time, the blowtorch position, the height of the mandrel straightening support, and the position of the mandrel straightening support.

[0030] Analyze the bow curvature distribution curves of the mandrel before and after straightening in the historical data to obtain the bow curvature changes;

[0031] Based on the changes in the length, outer diameter, and curvature of the mandrel before straightening in the historical data, the mandrel straightening process parameters of the straightening device are adjusted.

[0032] In some embodiments, the method further includes adjusting the stretching process parameters, specifically including:

[0033] Retrieve historical data over a period of time, including: the curvature distribution curve of the extended mother rod, and the extension process parameters for each start-up of the extension tower, including the extension rate, hydrogen and oxygen gas flow rate, and furnace temperature.

[0034] Analyze the curvature distribution curve of the extended mother rod in the historical data to obtain the curvature variation;

[0035] Based on the changes in the curvature, the extended process parameters in the historical data are analyzed to identify anomalies and correct them.

[0036] In some embodiments, after straightening the out-of-standard points, the following steps are also included:

[0037] The curvature of the mandrel was measured again to confirm that it was qualified;

[0038] If the result is not up to standard, mark the location and value of the point that exceeds the standard, and then recalibrate the point that exceeds the standard.

[0039] In some embodiments, the calibration rod process parameters from multiple straightening processes are merged to obtain updated calibration rod process parameters.

[0040] The calibration rod process parameters include the hydrogen-oxygen flame flow rate of the blowtorch, the burning time, the blowtorch position, the height of the calibration rod support, and the position of the calibration rod support.

[0041] The beneficial effects of the technical solution provided in this application include:

[0042] This application provides a mandrel curvature calibration system and method. Because it uses a central control device for full control, it eliminates human factors from interfering with product quality, accurately straightens the mandrel, improves processing efficiency, and solves the hidden danger of subsequent optical fiber preform core package concentricity failure due to excessive mandrel curvature.

[0043] Meanwhile, this application utilizes the concept of big data analysis, which can continuously improve the process level of the equipment through data accumulation and feedback. By improving the extension process parameters of the extension tower, the curvature of the mandrel can be improved, so that the curvature of the extended mandrel can directly meet the requirements. By improving the calibration process parameters of the calibration device, the curvature of the mandrel can be calibrated more efficiently and accurately. Attached Figure Description

[0044] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0045] Figure 1 A block diagram of a mandrel bow curvature calibration system provided in an embodiment of this application;

[0046] Figure 2 The provided embodiments of this application show the mandrel curvature distribution curves of multiple products under the same extended process parameters over a period of time.

[0047] Figure 3 A schematic diagram illustrating the fluctuation of hydrogen and oxygen gas flow rate over time as provided in this application embodiment;

[0048] Figure 4 A fitting graph of the predicted and actual values ​​of bow curvature provided in the embodiments of this application;

[0049] Figure 5 The curve of the curvature distribution of the mandrel produced by the No. 1 production line provided in this application embodiment over a period of time;

[0050] Figure 6 The curvature distribution curve of the mandrels produced by production line No. 3 provided in the embodiments of this application within the same time period;

[0051] Figure 7 Distribution diagrams of mandrel curvature in multiple production lines provided for embodiments of this application;

[0052] Figure 8 Box plots of mandrel curvature for multiple production lines provided in embodiments of this application;

[0053] Figure 9 The curvature distribution curve of the mandrel provided in the embodiments of this application;

[0054] Figure 10 The extension velocity distribution curve provided for the embodiments of this application;

[0055] Figure 11 The furnace body temperature distribution curve provided in the embodiments of this application;

[0056] Figure 12 The flow distribution curve of the hydrogen-oxygen flame provided in the embodiments of this application.

[0057] In the diagram: 1. Central control equipment; 2. Bar alignment device; 20. Bar alignment lathe; 21. Blowtorch; 22. Bar alignment bracket; 3. Intelligent robot; 30. X-axis diameter gauge; 31. Y-axis diameter gauge; 32. Storage cylinder; 33. Robotic arm; 4. Extension tower. Detailed Implementation

[0058] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0059] See Figure 1As shown in the figure, this application provides a mandrel curvature calibration system, which includes a calibration device, an intelligent robot, and a central control device. The calibration device includes a calibration lathe, a blowtorch movably mounted on the calibration lathe, and a calibration bracket. The central control device is connected to the intelligent robot, the blowtorch, and the calibration bracket, and is used to: determine the cutting position on the mother rod according to the selected, input, or received outer diameter and length of the completed extended mother rod, and the requirements of the next process; control the intelligent robot to cut a mandrel from the mother rod, measure the mandrel length, outer diameter, and curvature to form a curvature distribution curve in the length direction of the mandrel, and mark the location and value of the out-of-calibration points; and transfer the mandrel to the calibration device; and control the calibration device to straighten the out-of-calibration points.

[0060] The system provided in this application embodiment involves a central control device determining the cutting position on the mother rod based on the outer diameter and length of the extended mother rod and the requirements of the next process. An intelligent robot then performs the cutting, measuring the length, outer diameter, and curvature of the core rod to create a curvature distribution curve along its length. By comparing this curve with a curvature threshold, it's possible to determine if the curvature exceeds the limit. If so, the location and value of the excess point are marked. Finally, the system is sent to a rod alignment device, where the burner and alignment bracket are controlled to straighten each excess point. Because the entire process is controlled by a central control device, human error is eliminated, product quality is precisely aligned, processing efficiency is improved, and the potential for subsequent fiber optic preform core-cladding concentricity defects due to excessive core rod curvature is eliminated.

[0061] See Figure 1 As shown, the above-mentioned calibration device includes a calibration lathe, a blowtorch, and a calibration support. Both the blowtorch and the calibration support can be moved on the calibration lathe. Using a central control device, the flow rate of the hydrogen-oxygen flame, the burning time, and the position of the blowtorch can be controlled. The height and position of the calibration support can also be controlled. The blowtorch is used to burn and soften the excess point, and the height of the calibration support is adjusted to adjust the curvature of the excess point.

[0062] See Figure 1 As shown, the intelligent robot includes a movable X-axis diameter gauge and a Y-axis diameter gauge to measure the mandrel. The robotic arm can cut the mother rod and hold the mandrel. During the transfer process, the robotic arm can put the mandrel into a storage tube.

[0063] The requirements for the next process are specifically determined by actual production. For example, if the next process requires a mandrel length of 1500mm and an outer diameter requirement of 40mm±0.5mm, then start from one end of the already extended master rod, find the area where the outer diameter is qualified, and cut off a length of 1500mm.

[0064] The aforementioned central control equipment has multiple ways to obtain the outer diameter and length of the extended mother rod and the requirements of the next process.

[0065] For example, the central control equipment has a display screen that can show various commonly used specifications of mother rods and the requirements for the next process, which the user can simply select.

[0066] For example, the central control equipment has a display screen with input boxes. Users only need to input the outer diameter and length of the extended mother rod and the requirements for the next process in the input boxes.

[0067] For example, the central control equipment is connected to the extension tower and the OVD equipment. The extension tower sends the outer diameter and length of the completed extension of the mother bar to the central control equipment, and the OVD equipment sends the requirements for the next process to the central control equipment. The central control equipment only needs to receive the data.

[0068] For master rods of the same specifications, the locations and values ​​of the excess curvature points of the mandrels obtained by the extension tower under the same conditions are usually fixed. Therefore, the calibration process parameters for mandrels that are calibrated to the qualified state by the calibration device can be determined in advance.

[0069] After a straightening process, the mandrel's curvature should typically be within acceptable limits. However, for added assurance, in some preferred embodiments, the central control device is also used to: after the mandrel straightening device has processed all the out-of-range points, control the intelligent robot to remove the mandrel from the mandrel straightening device and measure the mandrel's curvature again to confirm it is within acceptable limits. If it is not within acceptable limits, mark the location and value of the out-of-range points and send it back to the mandrel straightening device for another straightening process.

[0070] If a mandrel requires multiple straightening operations to pass inspection, it indicates a problem with the current straightening process parameters. Subsequent mandrels may also require multiple straightening operations to pass inspection. To improve efficiency, in some preferred embodiments, the central control device is also used to: when a mandrel is confirmed to be qualified after multiple straightening operations, merge the straightening process parameters from the multiple operations of the straightening device to obtain updated straightening process parameters, so that the next mandrel can pass inspection in a single straightening operation using the updated straightening process parameters. The straightening process parameters include the hydrogen-oxygen flame flow rate of the blowtorch, the burning time, the blowtorch position, the height of the straightening support, and the position of the straightening support.

[0071] For example, if the only difference in the calibration process parameters is the burning time, then during the merging process, the burning times are added together and used as the burning time for the updated calibration process parameters, while the other parameters remain unchanged.

[0072] During the mandrel straightening process using a mandrel straightening device, a large amount of data is generated, which is often not utilized. Therefore, in order to fully utilize this large amount of data to guide the mandrel straightening process, improve the process, and enhance the effectiveness and efficiency of mandrel straightening, in some preferred embodiments, the system also includes a storage unit; the central control device is also connected to the storage unit and is used for:

[0073] The length and outer diameter of the mandrel before straightening, the curvature distribution curves before and after straightening, and the mandrel straightening process parameters for each operation of the mandrel straightening device are stored in the storage unit. The mandrel straightening process parameters include the hydrogen-oxygen flame flow rate of the blowtorch, the burning time, the blowtorch position, the height of the mandrel straightening support, and the position of the mandrel straightening support.

[0074] The central control equipment is also used for:

[0075] Retrieve historical data from the storage unit over a period of time and analyze the curvature distribution curves of the mandrel before and after straightening in the historical data to obtain the curvature change.

[0076] Based on historical data on the changes in the length, outer diameter, and curvature of the mandrel before straightening, the mandrel straightening process parameters of the straightening device are adjusted.

[0077] For example, the central control equipment analyzed historical data from recent months and found that in the past two weeks, the change in mandrel curvature before and after straightening decreased by 0.2 mm compared to the previous month. Further analysis of the mandrel's outer diameter before straightening revealed that the average outer diameter had decreased by 2 mm compared to the previous month, while the height of the mandrel straightening support remained unchanged. This was reported to the engineers, who discovered that the mandrel straightening support was not making sufficient contact with the mandrel during the straightening process, thus the curvature was not effectively calibrated. Based on this, the relationship between the mandrel straightening support height and the mandrel's outer diameter was adjusted, and the mandrel curvature was subsequently effectively controlled.

[0078] As can be seen, this preferred embodiment utilizes the concept of big data analysis, which can continuously improve the process level of the equipment through data accumulation and feedback. By improving the calibration process parameters of the calibration device, the curvature of the mandrel can be calibrated more efficiently and accurately.

[0079] During the extension process of the master rod using the extension tower, a large amount of data is generated. This data is often unused, and abnormal extension process parameters in the extension tower can affect the curvature data of the master rod, ultimately impacting the curvature of the mandrel. Therefore, to fully utilize this large amount of data to guide the extension process, improve process efficiency, and increase the yield of directly qualified mandrels after extension, in some preferred embodiments, the system also includes a storage unit. The central control device is also connected to the storage unit and the extension tower and is used for:

[0080] Based on the curvature distribution curve of the mandrel before straightening, the curvature distribution curve of the extended mother rod is formed.

[0081] The curvature distribution curve of the extended mother rod and the extension process parameters for each start-up of the extension tower are stored in the storage unit. The extension process parameters include extension rate, hydrogen and oxygen gas flow rate, and furnace temperature.

[0082] The central control equipment is also used for:

[0083] Retrieve historical data from the storage unit over a period of time and analyze the curvature distribution curve of the extended mother rod in the historical data to obtain the curvature change.

[0084] Based on the changes in bow curvature, we analyze the extended process parameters in historical data, identify anomalies, and correct them.

[0085] For example, as an example, the central control equipment, combining historical data over a period of time, provides engineers with the mandrel bow curvature distribution curve under the current extended process parameters. (See [link to relevant documentation]). Figure 2 As shown, under the same extended process parameters, the curves of mandrel curvature distribution of multiple products within a certain period of time are shown. The horizontal axis is the position coordinate of the measurement point on the mandrel, and the vertical axis is the curvature. It can be seen that the curvature of the mandrel generally increases from left to right.

[0086] Further analysis revealed fluctuations in the flow rate of hydrogen and oxygen gas during the extension process, and see [reference needed]. Figure 3 As shown, the fluctuation of hydrogen and oxygen gas flow rate gradually increases as production time progresses. The horizontal axis represents production time, and the vertical axis represents hydrogen and oxygen gas flow rate.

[0087] It is evident that fluctuations in the hydrogen and oxygen gas flow rate may affect the heating degree of the mandrel, thereby impacting the mandrel's extension accuracy. Further correlation analysis was conducted between hydrogen and oxygen gas flow rate fluctuations and mandrel curvature. Based on this correlation analysis and a regression model, the scatter plot between the actual mandrel curvature value +0.1 and the predicted value is shown below. Figure 4 As shown, Figure 4 This is a graph showing the fit between the actual and predicted values. The horizontal axis represents the position coordinates of the measurement point on the mandrel, and the vertical axis represents the curvature. Figure 4 As can be seen, the distribution trends of the actual and predicted values ​​of the six samples are roughly the same. Among them, the distribution range of two samples is relatively concentrated, and the fluctuation range of the predicted values ​​is also small, both within 0.075. The predicted indicators of the three samples are more dispersed.

[0088] Sample number Mean Squared Error (MSE) Mean Absolute Error (MAE) R-squared Regression indicator 1 6.93E-05 0.006646576 0.547836 78 2 1.23E-05 0.002804283 0.874289 74 3 1.53E-05 0.003114565 0.94199 74 4 4.70E-05 0.005261137 0.893261 75 5 4.21E-05 0.0046075 0.929895 78 6 2.61E-05 0.004058855 0.823351 74

[0089] In this analysis, the mean squared error and the MSE value of all six samples were small, indicating that the prediction model has very good accuracy in describing the experimental data.

[0090] Based on the results of this big data analysis, the engineers decided to calibrate the accuracy of the MFC (mass flow controller) in the extension tower to control flow fluctuations, and finally verified the effectiveness of the improvement.

[0091] For example, the central control equipment combines historical data over a period of time to provide engineers with feedback on the product curvature distribution in extended processes.

[0092] See Figure 5 and Figure 6 As shown in the historical data trend chart, the bow curvature distribution of production line 1 and production line 3 shows opposite trends.

[0093] See Figure 5 As shown, the curve of the curvature of the mandrel produced on production line 1 over a period of time is shown. The horizontal axis is the position of the measurement point on the mandrel, and the vertical axis is the curvature. For production line 1, the curvature of the mandrel increases with the increase of the extension length.

[0094] See Figure 6 As shown, the curve of the mandrel curvature distribution of production line 3 within the same period of time is shown. The horizontal axis is the position of the measurement point on the mandrel, and the vertical axis is the curvature. For production line 3, the curve is the opposite. As the extension length increases, the mandrel curvature decreases.

[0095] See Figure 7 and Figure 8 As shown, the average extension length and curvature of multiple production lines are compared. Figure 7 This is a distribution diagram of mandrel curvature across multiple production lines. The horizontal axis represents the coordinates of the measurement points on the mandrel, and the vertical axis represents the curvature. Figure 8 This is a box plot of mandrel arch curvature for multiple production lines. The horizontal axis represents different production lines, and the vertical axis represents the distribution of the average mandrel arch curvature of all mandrels in that production line.

[0096] Based on the above analysis, engineers are advised to focus on analyzing the equipment differences between production line 1 and production line 3 to identify the root cause of the problem.

[0097] For example, as a case study, the central control unit, combining historical data over a period of time, reports to engineers that the six recently produced products generally exhibit a large degree of curvature at the 300-position. (See [link to relevant documentation]). Figure 9 The figure shows the curvature distribution curve of mandrels produced by a certain production line within the same period of time. The horizontal axis is the position of the measurement point on the mandrel, and the vertical axis is the curvature.

[0098] Meanwhile, the central control equipment retrieves curves of recent production processes, including extension speed, furnace temperature, and hydrogen / oxygen gas flow rate, to observe any abnormalities. (See below) Figure 10, Figure 11 and Figure 12 As shown, Figure 10 This is a curve showing the elongation speed distribution during each start-up of a production line producing mandrels within the same time period. The horizontal axis represents production time, and the vertical axis represents elongation speed. Figure 11 This is a furnace temperature distribution curve for a production line during the same period of time, showing the furnace temperature at each start-up. The horizontal axis represents production time, and the vertical axis represents furnace temperature. Figure 12 This is a curve showing the flow rate distribution of the hydrogen-oxygen flame during each start-up process of a certain production line when producing mandrels within the same time period. The horizontal axis represents the production time, and the vertical axis represents the flow rate of the hydrogen-oxygen flame.

[0099] Fitting analysis was performed on the curves of the relevant parameters. First, the influence of gas flow rate was eliminated because the gas flow rate of the six samples did not fluctuate.

[0100] Secondly, the study investigated the effect of furnace temperature on bow curvature and found that the furnace temperature change curves of the six samples were the same, indicating that the equipment was not abnormal. The furnace temperature at 300 mm was relatively high, which may be an important factor affecting bow curvature. However, the bow curvature of the six samples in the later part of the curves was significantly different, while the furnace temperature was the same, indicating poor fitting. Therefore, the prediction fitting of the effect of furnace temperature on bow curvature was not accurate.

[0101] Finally, the effect of stretching speed on curvature was studied. Due to the characteristics of the stretching process, in order to obtain a higher glass utilization rate, the stretching speed is generally faster at about 300mm from the beginning of the stretching process. The glass is heated in the furnace for a relatively short time, is less affected by the equipment, and is more likely to maintain its original state. Theoretically, this may lead to a larger curvature.

[0102] The following table is obtained by fitting the distribution of extension velocity and curvature:

[0103] Sample number Mean Squared Error (MSE) Mean Absolute Error (MAE) R-squared Regression indicator 1 0.0000125 0.002386952 0.825401 62 2 0.0000321 0.001045089 0.910042 65 3 0.0000148 0.002056912 0.930241 65 4 0.0000356 0.004025041 0.854619 63 5 0.0000274 0.003105061 0.876356 67 6 0.0000213 0.001056081 0.890742 62

[0104] As can be seen from the table above, good fitting accuracy and fast starting extension speed are the main factors causing excessive curvature. Based on this data and the causes, the engineers made the following improvement hypothesis: increase the temperature of the starting furnace to allow the glass to be fully heated, thereby improving the starting curvature.

[0105] This application also provides a method for calibrating the curvature of a mandrel, which includes the following steps:

[0106] 101: Based on the outer diameter and length of the extended mother rod and the requirements of the next process, determine the cutting position on the mother rod;

[0107] Specifically, the central control equipment can determine the cutting position on the mother bar based on the selected, input, or received outer diameter and length of the extended mother bar, as well as the requirements of the next process.

[0108] For example, the central control equipment has a display screen that can show various commonly used specifications of mother rods and the requirements for the next process, which the user can simply select.

[0109] For example, the central control equipment has a display screen with input boxes. Users only need to input the outer diameter and length of the extended mother rod and the requirements for the next process in the input boxes.

[0110] For example, the central control equipment is connected to the extension tower and the OVD equipment. The extension tower sends the outer diameter and length of the completed extension of the mother bar to the central control equipment, and the OVD equipment sends the requirements for the next process to the central control equipment. The central control equipment only needs to receive the data.

[0111] 102: Cut the mandrel from the mother rod, measure the length, outer diameter and curvature of the mandrel to form a curvature distribution curve along the length of the mandrel, and mark the location and value of the out-of-standard points.

[0112] Specifically, the central control equipment controls the intelligent robot to perform cutting and measurement work, and uses the measured data to form a curvature distribution curve in the length direction of the mandrel, and marks the location and value of the out-of-standard points. Then, the intelligent robot transfers the mandrel to the calibration device.

[0113] 103: The central control equipment controls the operation of the torch and the rod support of the calibration rod device to straighten out points that exceed the standard.

[0114] 104: Next, measure the mandrel curvature again to confirm it is acceptable; if it is not acceptable, mark the location and value of the excess points, and straighten the excess points again until it is acceptable. Then, combine the mandrel straightening process parameters from multiple straightening processes to obtain updated mandrel straightening process parameters for subsequent mandrel straightening; the mandrel straightening process parameters include the hydrogen-oxygen flame flow rate of the blowtorch, the burning time, the blowtorch position, the height of the mandrel straightening support, and the position of the mandrel straightening support.

[0115] During the mandrel straightening process using a mandrel straightening device, a large amount of data is generated, which is often not utilized. Therefore, in order to fully utilize this large amount of data to guide the mandrel straightening process, improve the process, and enhance the effectiveness and efficiency of mandrel straightening, in some preferred embodiments, the method further includes adjusting the mandrel straightening process parameters. Specifically, adjusting the mandrel straightening process parameters includes:

[0116] 201: Retrieve historical data for a period of time. The historical data includes: the length and outer diameter of the mandrel before straightening, the curvature distribution curves before and after straightening, and the mandrel straightening process parameters for each operation of the mandrel straightening device. The mandrel straightening process parameters include the hydrogen-oxygen flame flow rate of the blowtorch, the burning time, the blowtorch position, the height of the mandrel straightening support, and the position of the mandrel straightening support.

[0117] 202: Analyze the bow curvature distribution curves of the mandrel before and after straightening in historical data to obtain the bow curvature changes.

[0118] 203: Based on the changes in the length, outer diameter, and curvature of the mandrel before straightening in historical data, adjust the mandrel straightening process parameters of the straightening device.

[0119] The above implementation utilizes the concept of big data analysis, which can continuously improve the process level of the equipment through data accumulation and feedback. By improving the calibration process parameters of the calibration device, the curvature of the mandrel can be calibrated more efficiently and accurately.

[0120] During the extension process of the master rod using an extension tower, a large amount of data is generated, which is often not utilized. Furthermore, abnormal extension process parameters in the extension tower can affect the curvature data of the master rod, ultimately impacting the curvature of the mandrel. Therefore, to fully utilize this large amount of data to guide the extension process, improve the process, and increase the yield of directly qualified mandrels after extension, in some preferred embodiments, the method further includes adjusting the extension process parameters. Specifically, adjusting the extension process parameters includes:

[0121] 301: Retrieve historical data for a period of time. The historical data includes: the curvature distribution curve of the extended master rod, and the extension process parameters for each start-up of the extension tower, including the extension rate, hydrogen and oxygen gas flow rate, and furnace temperature.

[0122] 302: Analyze the bow curvature distribution curve of the extended mother rod in historical data to obtain the bow curvature variation.

[0123] 303: Based on the changes in bow curvature, analyze the extended process parameters in historical data, identify anomalies, and correct them.

[0124] The above implementation utilizes the concept of big data analysis, which can continuously improve the process level of the equipment through data accumulation and feedback. By improving the extension process parameters of the extension tower, the curvature of the mandrel can be improved, so that the curvature of the extended mandrel can directly meet the requirements.

[0125] In the description of this application, it should be noted that the terms "upper," "lower," etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Unless otherwise expressly specified and limited, the terms "installed," "connected," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication between two elements. For those skilled in the art, the specific meaning of the above terms in this application can be understood according to the specific circumstances.

[0126] It should be noted that in this application, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0127] The above description is merely a specific embodiment of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

Claims

1. A mandrel curvature calibration system, characterized in that, It includes: A bar straightening device, comprising a bar straightening lathe, a blowtorch movably mounted on the bar straightening lathe, and a bar straightening bracket; Intelligent robots; The system includes a central control device connected to the intelligent robot, the blowtorch, and the alignment rod support. The central control device is used to: determine the cutting position on the mother rod based on the selected, input, or received outer diameter and length of the completed extension of the mother rod, and the requirements of the next process; control the intelligent robot to cut a mandrel from the mother rod, measure the mandrel's length, outer diameter, and curvature to form a curvature distribution curve along the mandrel's length, and mark the locations and values ​​of any points exceeding the standard; and transfer the mandrel to the alignment rod device; and control the alignment rod device to straighten the points exceeding the standard. The system also includes a storage unit; The central control device is also connected to the storage unit and is used to: store the length and outer diameter of the mandrel before straightening, the curvature distribution curves before and after straightening, and the mandrel straightening process parameters for each operation of the mandrel straightening device into the storage unit; The central control device is also used to: call up historical data of the storage unit over a period of time, and analyze the bow curvature distribution curve of the mandrel before and after straightening in the historical data to obtain the bow curvature change; and adjust the mandrel straightening process parameters of the straightening device based on the length and outer diameter of the mandrel before straightening and the bow curvature change in the historical data. The central control device is also used to: after the calibration device has straightened all the out-of-standard points, control the intelligent robot to remove the mandrel from the calibration device and measure the curvature of the mandrel again to confirm that it is qualified; if it is not qualified, mark the location and value of the out-of-standard point and send it back to the calibration device. The central control device is also used to: when the mandrel is confirmed to be qualified after multiple straightening operations, merge the mandrel straightening process parameters from the multiple operations of the mandrel straightening device to obtain updated mandrel straightening process parameters.

2. The mandrel curvature calibration system as described in claim 1, characterized in that: The calibration rod process parameters include the hydrogen-oxygen flame flow rate of the blowtorch, the burning time, the blowtorch position, the height of the calibration rod support, and the position of the calibration rod support.

3. The mandrel curvature calibration system as described in claim 1, characterized in that: The system also includes a storage unit; The central control device is also connected to the storage unit and the extension tower, and is used for: Based on the curvature distribution curve of the mandrel before straightening, the curvature distribution curve of the extended mother rod is formed. The curvature distribution curve of the extended mother rod and the extension process parameters for each start-up of the extension tower are stored in the storage unit. The extension process parameters include extension speed, hydrogen and oxygen gas flow rate, and furnace temperature. The central control device is also used for: The historical data of the storage unit over a period of time is retrieved, and the bow curvature distribution curve of the extended mother rod in the historical data is analyzed to obtain the bow curvature change. Based on the changes in the curvature, the extended process parameters in the historical data are analyzed to identify anomalies and correct them.

4. A method for calibrating the curvature of a mandrel, characterized in that, It includes the following steps: Based on the outer diameter and length of the extended mother rod, and the requirements of the next process, the cutting position is determined on the mother rod. Cut a mandrel from the mother rod, measure the length, outer diameter and curvature of the mandrel to form a curvature distribution curve along the length of the mandrel, and mark the locations and values ​​of the points exceeding the standard. The points exceeding the standard were straightened. The curvature of the mandrel was measured again to confirm that it was qualified; If it is not up to standard, mark the location of the point that exceeds the standard and the value of the excess, and then straighten the point that exceeds the standard again; The calibration rod process parameters from multiple straightening processes are merged to obtain updated calibration rod process parameters. The method further includes adjusting the calibration rod process parameters, which specifically includes: Retrieve historical data for a period of time. The historical data includes: the length and outer diameter of the mandrel before straightening, the curvature distribution curve before and after straightening, and the mandrel straightening process parameters for each operation of the mandrel straightening device. The mandrel straightening process parameters include the hydrogen-oxygen flame flow rate of the blowtorch, the burning time, the blowtorch position, the height of the mandrel straightening support, and the position of the mandrel straightening support. Analyze the bow curvature distribution curves of the mandrel before and after straightening in the historical data to obtain the bow curvature changes; Based on the changes in the length, outer diameter, and curvature of the mandrel before straightening in the historical data, the mandrel straightening process parameters of the straightening device are adjusted.

5. The mandrel curvature calibration method as described in claim 4, characterized in that: The method further includes adjusting the extension process parameters, which specifically includes: Retrieve historical data over a period of time, including: the curvature distribution curve of the extended mother rod, and the extension process parameters for each start-up of the extension tower, including the extension rate, hydrogen and oxygen gas flow rate, and furnace temperature. Analyze the curvature distribution curve of the extended mother rod in the historical data to obtain the curvature variation; Based on the changes in the curvature, the extended process parameters in the historical data are analyzed to identify anomalies and correct them.

Images