A double-wall corrugated pipe online staggered joint adjustment system and method

Abstract

The application relates to an online staggered adjustment system and method for a double-wall corrugated pipe. The online staggered adjustment system for the double-wall corrugated pipe comprises two brackets arranged oppositely, each of which is provided with a set of die assemblies, and each set of die assemblies is connected with a set of control assemblies; the die assembly comprises an annular track arranged on the bracket and a plurality of sectional toothed straight racks arranged along the annular track; the side of the annular track close to the other bracket is provided with a straight section; the control assembly comprises a driving member arranged on the bracket and a transmission member arranged at the output end of the driving member, and the transmission member is engaged with the sectional toothed straight rack; the driving member is used for controlling the moving speed of the sectional toothed straight rack, so that the sectional toothed straight racks of the two sets of die assemblies are one-to-one corresponding at the straight section and the staggered error is kept within a preset range. The application can avoid the problem that unilateral driving is prone to left-right stagger due to the transmission of the transmission member.

Description

Technical Field

[0001] This application relates to the field of double-wall corrugated pipe forming mold technology, and in particular to an online staggered adjustment system and method for double-wall corrugated pipes. Background Technology

[0002] Double-wall corrugated pipes are widely used in municipal drainage, sewage, and communication wiring due to their advantages such as high ring stiffness, corrosion resistance, light weight, and convenient construction. Their production process often employs continuous forming technology, requiring extremely high precision in the alignment of the forming molds. Misalignment of the mold is a common process problem in the production of double-wall corrugated pipes. Even slight misalignment can lead to defects such as raised parting marks, double eyelids, and uneven wall thickness in the formed pipe. In severe cases, it can even cause holes in the pipe, directly resulting in product scrap. Furthermore, the hard impact caused by misalignment can accelerate mold wear, damage precision mating surfaces, and significantly shorten the service life of the mold and forming equipment.

[0003] In current industry production processes, the transmission of molds on both sides generally adopts a single-sided drive method. That is, a driving component, such as a servo motor, is used on one side to drive the mold on that side, and then the mold on the other side is driven by transmission components such as gears and racks. This method can achieve synchronous movement of the molds on both sides. However, errors are easily generated during the transmission process of gears and racks, which can lead to misalignment of the molds on both sides, resulting in a number of problems caused by this misalignment.

[0004] Therefore, how to overcome the shortcomings of existing technologies and solve the problem of easy left-right misalignment in the traditional double-wall corrugated pipe production process is a problem to be solved in this technical field. Summary of the Invention

[0005] In view of the above-mentioned defects or improvement needs of the existing technology, and in order to solve the problem of easy left and right misalignment in the traditional double-wall corrugated pipe production process, this application provides an online misalignment adjustment system and method for double-wall corrugated pipes. By using a dual-side drive, the drive systems of the two molds (i.e., segmented grinding toothed racks) are made independent, avoiding the problem of left and right misalignment caused by the transmission of transmission components due to single-side drive.

[0006] The embodiments of this application adopt the following technical solutions: In a first aspect, this application provides an online staggered adjustment system for double-wall corrugated pipes, including two supports arranged opposite to each other, each support being provided with a set of mold components, and each set of mold components being connected to a set of control components; The mold assembly includes an annular track mounted on the support and a plurality of segmented, ground toothed spur racks slidably mounted along the annular track; the side of the annular track closest to the other support is configured as a straight segment. The control component includes a drive component mounted on the bracket and a transmission component mounted at the output end of the drive component. The transmission component meshes with the segmented grinding spur rack. The drive component is used to control the moving speed of the segmented grinding spur rack so that the segmented grinding spur racks of the two sets of mold assemblies correspond one-to-one at the straight section and the misalignment error is kept within a preset range.

[0007] By adopting the above technical solution, two sets of control components are set up to control the two sets of mold components respectively. This avoids the left-right misalignment problem caused by excessive transmission components and excessive transmission distance in single-sided drive. Furthermore, setting up two sets of control components can also realize online adjustment of mold misalignment during the double-wall corrugated pipe forming process. Specifically, by using the meshing cooperation between the segmented grinding toothed rack and the transmission component, the driving component precisely controls the moving speed of the segmented grinding toothed rack, ensuring that the segmented grinding toothed racks of the two sets of mold components correspond one-to-one in the straight section, controlling the misalignment error within the preset range, and completing the misalignment correction without stopping the machine, improving production efficiency, and ensuring the basic alignment accuracy of corrugated pipe forming.

[0008] In some embodiments, the annular track includes two tracks arranged symmetrically at the top and bottom, and the segmented ground toothed spur rack is provided with sliding blocks at both the top and bottom ends. The segmented ground toothed spur rack is slidably connected to the upper and lower tracks respectively through the sliding blocks at the top and bottom ends.

[0009] By adopting the above technical solution, the circular track is set as two symmetrical tracks. The segmented grinding spur rack is slidably connected to the track through sliding blocks at both ends, providing double-sided guidance and support for the movement of the segmented grinding spur rack. This avoids the problem of unilateral deviation and jamming of the segmented grinding spur rack during movement, and improves the stability and smoothness of the segmented grinding spur rack sliding along the circular track.

[0010] In some embodiments, the upper and lower tracks of the annular track are each provided with two inner and two outer grooves, and the upper and lower ends of the segmented grinding toothed rack are each provided with two sliding blocks distributed diagonally, so that each sliding block is located in a groove.

[0011] By adopting the above technical solution, two grooves, one inner and one outer, are set on the upper and lower tracks of the annular track. The sliding blocks of the segmented grinding spur rack are distributed diagonally and embedded in the grooves, realizing multi-directional limiting of the segmented grinding spur rack, restricting the radial movement of the segmented grinding spur rack, further ensuring the straightness of the movement of the segmented grinding spur rack, avoiding meshing failure and increased misalignment error caused by the offset of the segmented grinding spur rack, and improving transmission accuracy and mold alignment stability.

[0012] In some embodiments, the drive component includes a servo motor and a reducer connected to the servo motor, and the transmission component includes at least two meshing gears, one of which is disposed on the output shaft of the reducer, and the other gear meshes with the segmented ground spur rack and is rotatably disposed on the bracket.

[0013] By adopting the above technical solution, a servo motor paired with a reducer is used as the driving component to provide precise and controllable rotational power. Power is transmitted through a transmission component with at least two meshing grinding gears, achieving smooth power transmission and speed regulation. This ensures the precision of the meshing between the transmission component and the segmented grinding spur rack, making the control of the moving speed of the segmented grinding spur rack by the driving component more precise and improving the accuracy of misalignment adjustment.

[0014] In some embodiments, the transmission component further includes a plurality of driven grinding gears rotatably mounted on the bracket, the driven grinding gears being distributed along the inner side of the annular track, and each driven grinding gear meshing with the segmented grinding spur rack.

[0015] By adopting the above technical solution, multiple driven grinding gears that mesh with the segmented grinding spur rack are set on the inner side of the annular track, forming multi-point meshing support for the movement of the segmented grinding spur rack. This prevents the segmented grinding spur rack from bending or shifting due to its own weight or meshing force, ensuring the stability of the segmented grinding spur rack meshing along the entire annular track. At the same time, it makes the force on the segmented grinding spur rack more uniform, extending the service life of the segmented grinding spur rack and the grinding gears used for transmission.

[0016] In some embodiments, the brackets are slidably mounted on a movable platform, and two brackets are connected by an electric lead screw assembly, which is used to move the two brackets closer to or further apart from each other.

[0017] By adopting the above technical solution, the bracket is slidably set on the movable platform, and the two brackets are connected by an electric screw assembly to make them move closer or further apart. The distance between the two sets of mold assemblies can be flexibly adjusted according to the specifications and dimensions of the double-wall corrugated pipe, so that the system can be adapted to the production of double-wall corrugated pipes of different diameters, improve the versatility and adaptability of the system, and complete the production switch of different specifications of products without changing the mold bracket.

[0018] In some embodiments, a detection device is also included, comprising a displacement sensor and / or a mold alignment detection unit, wherein the displacement sensor includes an absolute encoder connected to the control component, and the mold alignment detection unit includes a laser scanner and / or a vision inspection system disposed at the mold exit.

[0019] By adopting the above technical solution, a detection device consisting of a displacement sensor and / or a mold alignment detection unit is set up to achieve accurate detection and accurate collection of misalignment errors, providing real and reliable detection data for misalignment adjustment and improving the accuracy of misalignment adjustment.

[0020] Secondly, this application provides an online staggered adjustment method for double-wall corrugated pipes, applied to the online staggered adjustment system for double-wall corrugated pipes described in the first aspect, comprising: The misplanting error is measured by a detection device. If the misplanting error exceeds the preset range, the misplanting error is used as the target adjustment amount. The two sets of drive components are controlled separately according to the target adjustment amount, so as to produce a speed difference between the two sets of drive components and reduce the misalignment error. The misalignment error is measured again by the detection device. If the misalignment error falls within the preset range, the adjustment is completed, and the two sets of drive components are controlled to return to pure synchronous mode.

[0021] By adopting the above technical solution, the target adjustment amount is determined based on the misalignment error data of the detection device. The misalignment error is corrected online by controlling the speed deviation of the drive component. After the adjustment is completed, the drive component is restored to pure synchronous mode, forming a closed-loop misalignment adjustment process of detection-adjustment-verification-reset. This achieves rapid and accurate correction of misalignment error, ensures the corrugated pipe forming quality, and avoids production capacity loss caused by downtime adjustment.

[0022] In some implementations, controlling the two sets of drive components separately according to the target adjustment amount to create a speed deviation between the two sets of drive components, thereby reducing misalignment errors, specifically includes: The target adjustment amount is analyzed in a graded manner, and the error is divided into mild, moderate and severe error levels according to the magnitude of the misalignment error. Different error levels are matched with preset drive component speed deviation gradient and adjustment rate. Among them, severe error is matched with two-stage parameters of maximum speed deviation gradient and high-speed coarse adjustment rate, minimum speed deviation gradient and low-speed fine adjustment rate; moderate error is matched with medium speed deviation gradient and medium-speed adjustment rate; and mild error is matched with minimum speed deviation gradient and low-speed adjustment rate. At the same time, a preset adjustment switching threshold is set. The adjustment switching threshold is greater than the preset range and is within the mild error range. It serves as the switching node between coarse and fine adjustment for severe errors, as well as the unified trigger node for speed deviation gradient and adjustment rate downgrade in all error level adjustments. For severe errors, the rotation speed of the two sets of drive components is first controlled according to the maximum speed deviation gradient and high-speed coarse adjustment rate to complete the coarse adjustment. When the detection device detects that the error has dropped to the adjustment switching threshold, the system switches to the minimum speed deviation gradient and low-speed fine adjustment rate to continue the adjustment. For moderate errors, the rotation speed of the drive components is directly controlled according to the matched speed deviation gradient and adjustment rate. For slight errors, precise fine adjustment is performed directly according to the matched speed deviation gradient and adjustment rate. When the detection device detects that the misalignment error has dropped to the adjustment switching threshold, it gradually reduces the speed deviation gradient of the drive component and decreases the adjustment rate until the misalignment error falls into the preset range.

[0023] By adopting the above technical solution, the target adjustment amount is analyzed and classified in a tiered manner, and differentiated drive component control parameters are matched. At the same time, a preset quantified adjustment switching threshold is used as a unified trigger node for further downgrading, realizing full-process quantitative control of misalignment adjustment. Severe errors are quickly corrected by high-speed coarse adjustment and reduced to the range of minor errors before switching to low-speed fine adjustment. Medium errors are adjusted smoothly at medium speed, and minor errors are adjusted precisely at low speed throughout the process. Moreover, after all error levels are reduced to the adjustment switching threshold, they are downgraded step by step to achieve smooth error convergence. This not only avoids the efficiency loss of adjusting at low speed throughout the process for severe errors, but also eliminates the risk of overshoot in the adjustment of various errors from the root. The entire process is quantified and triggered by the detection device, without fuzzy control logic, which ensures the controllability and repeatability of the adjustment process, greatly improving the accuracy and efficiency of online misalignment adjustment of double-wall corrugated pipes, and effectively solving the technical problem that it is difficult to balance accuracy and efficiency in traditional online adjustment.

[0024] In some implementations, it also includes: During the adjustment process, the position data of the segmented grinding straight rack of the two sets of mold components on the straight section of the circular track, the running parameters of the drive components, and the misalignment error detection data of the detection device are collected in real time to construct a real-time data model of the adjustment process. The data model is used to predict the trend of the misalignment error. If the misalignment error is predicted to overshoot to outside the preset range, the speed deviation of the drive component is corrected in advance by reverse compensation. After the adjustment is completed, the target adjustment amount, error level, matching speed deviation gradient and adjustment rate, adjustment switching threshold trigger time, adjustment duration and final error value are stored to form a historical database of mis-cropping adjustments. When the detection device detects the same or similar mis-cropping error again, it directly retrieves the matching parameters from the historical database to control the drive components.

[0025] By adopting the above technical solutions, a real-time data model for the adjustment process is constructed, and trend prediction and reverse compensation are performed. This upgrades the system from passive adjustment to active prediction and compensation correction, completely avoiding the problem of adjustment overshoot. At the same time, a historical database of staggered cropping adjustments is established to achieve rapid matching and parameter adjustment for similar errors, significantly shortening the adjustment time for subsequent similar staggered cropping errors, improving the intelligent adjustment level of the system, and providing data support for preventive maintenance of equipment and process optimization.

[0026] Compared with the prior art, the beneficial effects of this application include, but are not limited to, the following: 1. Setting up two sets of control components to control the two sets of mold components respectively can avoid the left-right misalignment problem caused by excessive transmission parts and excessive transmission distance in single-sided drive. Furthermore, setting up two sets of control components can also realize online adjustment of mold misalignment during the double-wall corrugated pipe forming process. Specifically, by using the meshing cooperation between the segmented grinding toothed rack and the transmission component, the driving component precisely controls the moving speed of the segmented grinding toothed rack, ensuring that the segmented grinding toothed racks of the two sets of mold components correspond one-to-one in the straight section, controlling the misalignment error within the preset range, and completing the misalignment correction without stopping the machine, improving production efficiency, while ensuring the basic alignment accuracy of corrugated pipe forming.

[0027] 2. The target adjustment amount is analyzed and classified in a tiered manner, and differentiated drive component control parameters are matched. At the same time, a preset quantified adjustment switching threshold is used as a unified trigger node for further downgrading, realizing full-process quantitative control of misaligned adjustment. Severe errors are quickly corrected by high-speed coarse adjustment and reduced to the range of minor errors before switching to low-speed fine adjustment. Medium errors are adjusted smoothly at medium speed, and minor errors are adjusted precisely at low speed throughout the process. Moreover, after all error levels are reduced to the adjustment switching threshold, they are downgraded step by step to achieve smooth error convergence. This avoids the efficiency loss of adjusting at low speed throughout the process for severe errors and eliminates the risk of overshoot in the adjustment of various errors from the root. The entire process is triggered by the detection device in a quantified manner, without fuzzy control logic, which ensures the controllability and repeatability of the adjustment process, greatly improving the accuracy and efficiency of online misaligned adjustment of double-wall corrugated pipes, and effectively solving the technical problem that it is difficult to balance accuracy and efficiency in traditional online adjustment.

[0028] 3. Construct a real-time data model for the adjustment process and perform trend prediction and reverse compensation, upgrading from passive adjustment to active prediction + compensation correction, completely avoiding the problem of adjustment overshoot; at the same time, establish a historical database of mis-cropping adjustments to achieve rapid matching and parameter adjustment of similar errors, significantly shortening the adjustment time of subsequent similar mis-cropping errors, improving the intelligent adjustment level of the system, and providing data support for preventive maintenance of equipment and process optimization. Attached Figure Description

[0029] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the embodiments of this application will be briefly described below. Obviously, the 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.

[0030] Figure 1 This is a schematic diagram of the structure of an online staggered adjustment system for double-walled corrugated pipes provided in an embodiment of this application; Figure 2 Detailed structural diagrams of the mold assembly and control assembly provided in the embodiments of this application; Figure 3 This is a schematic diagram of the sliding block and groove fitting together according to an embodiment of this application; Figure 4 A flowchart illustrating an online staggered adjustment method for double-walled corrugated pipes provided in this application embodiment.

[0031] In the diagram: 1. Support; 2. Mold assembly; 201. Circular track; 2011. Groove; 202. Segmented ground spur rack; 2021. Sliding block; 3. Control assembly; 301. Drive component; 302. Transmission component; 303. Driven ground gear; 4. Movable platform; 5. Electric lead screw assembly. Detailed Implementation

[0032] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0033] Furthermore, the technical features involved in the various embodiments of this application described below can be combined with each other as long as they do not conflict with each other. This application will now be described in detail with reference to the accompanying drawings and embodiments. Example 1

[0034] This application provides an online misalignment adjustment system for double-wall corrugated pipes, which is suitable for the continuous molding production of HDPE double-wall corrugated pipes for municipal drainage and sewage. It can avoid the problem of left and right misalignment caused by the transmission of transmission components in traditional single-sided drive, and can realize online precise adjustment of mold misalignment without stopping the machine during the molding process, effectively ensuring the molding quality of corrugated pipes and improving production efficiency.

[0035] As shown in Figure 1, the online staggered adjustment system for double-wall corrugated pipes provided in this embodiment includes two supports 1 arranged opposite each other, mold assemblies 2 respectively mounted on the two supports 1, control components 3 corresponding to each set of mold assemblies 2, a movable platform 4 for supporting the supports 1, an electric screw assembly 5 connecting the two supports 1, and a detection device for detecting staggered errors. The two supports 1 are symmetrically slidably mounted on the upper surface of the movable platform 4. Multiple parallel tracks can be set on the movable platform 4, and the bottom of the supports 1 is slidably mounted on the tracks. Multiple sets of electric screw assemblies 5 are arranged along the sliding track direction of the two supports 1. The two ends of each set of electric screw assemblies 5 are fixedly connected to the two supports 1 respectively, and are used to drive the two supports 1 to make linear movements that move closer or further apart along the track direction. Each set of mold assemblies 2 is connected to a set of control components 3. The detection device is connected to the controller. The staggered error data collected by the detection device is transmitted to the controller. The controller controls the control components 3 to complete the online adjustment of the mold staggered error.

[0036] refer to Figure 2 As shown, in some embodiments, the mold assembly 2 is the basic transmission component for forming double-walled corrugated pipes, used to drive the forming mold to move along a preset trajectory, and includes an annular track 201 and several segmented ground toothed spur racks 202.

[0037] The annular track 201 is fixedly mounted on the support 1. It includes two annular tracks arranged symmetrically at the top and bottom. The side of the annular track 201 on each support 1 that is closer to the other support 1 is a straight section. This straight section is the mold forming section of the double-walled corrugated pipe and is the key area for staggered adjustment. The upper and lower tracks of the annular track 201 are provided with two grooves 2011 that are symmetrical inside and outside. The grooves 2011 are arranged along the extension direction of the track to provide sliding and limiting space for the sliding block 2021 of the segmented grinding straight tooth rack 202.

[0038] Furthermore, several segmented ground spur racks 202 are evenly distributed along the extension direction of the annular track 201, and all can be slidably arranged along the annular track 201; part of the tooth surface of the segmented ground spur racks 202 faces the inner side of the bracket 1, for meshing with the transmission component 302 of the control assembly 3; Reference Figure 3 As shown, two sliding blocks 2021 are fixedly provided at both the upper and lower ends of the segmented grinding spur rack 202. The two sliding blocks 2021 are distributed diagonally along the segmented grinding spur rack 202, and each sliding block 2021 is embedded in a groove 2011 of the corresponding track of the annular track 201, so as to realize the sliding connection between the segmented grinding spur rack 202 and the annular track 201. At the same time, through the cooperation between the groove 2011 and the sliding block 2021, the radial movement of the segmented grinding spur rack 202 is restricted, ensuring its sliding stability.

[0039] Furthermore, the outer walls of several segmented grinding straight tooth racks 202 are connected to a forming mold module. The forming mold module moves along the annular track 201 with the segmented grinding straight tooth racks 202 to complete the cycle of mold closing, forming, and mold opening of the double-walled corrugated pipe. The segmented grinding straight tooth racks 202 of the two sets of mold components 2 correspond one-to-one at the straight section of the annular track 201 to ensure the precise mold closing of the forming mold module.

[0040] refer to Figure 2 In some embodiments, the control component 3 is the power and control core for staggered adjustment, used to drive the segmented grinding spur rack 202 to move along the annular track 201 and precisely control its moving speed. It includes a drive component 301, a transmission component 302 and a driven grinding gear 303.

[0041] The drive component 301 is fixedly mounted on the bracket 1 and includes a servo motor and a precision reducer. The output shaft of the servo motor is coaxially and fixedly connected to the input end of the precision reducer, and the output end of the precision reducer is connected to the transmission component 302. The servo motor can be an AC permanent magnet servo motor, which features high resolution and high response speed, and can achieve precise stepless speed adjustment. The precision reducer has a reduction ratio of 1:20, which is used to convert the high-speed rotational motion of the servo motor into low-speed, high-torque power output, ensuring transmission stability. It should be noted that the drive component 301 can also be configured with other types of drive structures, such as cylinders or hydraulic transmission components.

[0042] Furthermore, the transmission component 302 includes a driving ground gear and an intermediate ground gear. The driving ground gear is coaxially fixed on the output shaft of the precision reducer, while the intermediate ground gear is rotatably mounted on the bracket 1 via a rotating shaft and meshes with the driving ground gear. The intermediate ground gear also meshes with the tooth surface of the segmented ground spur rack 202, achieving a smooth power transmission from the drive component 301 to the segmented ground spur rack 202. The intermediate ground gear is preferentially positioned at the corner of the annular track 201 to directly mesh with the segmented ground spur rack 202 at the corner, preventing misalignment of the segmented ground spur rack 202 at the corner.

[0043] Furthermore, multiple driven ground gears 303 are rotatably mounted on the inner side of the annular track 201 via rotating shafts, and all mesh with the tooth surfaces of the segmented ground spur rack 202. The driven ground gears 303 are evenly distributed along the connection between the arc-shaped and straight sections of the annular track 201, forming multi-point meshing support for the segmented ground spur rack 202, ensuring its stability during meshing along the entire length of the annular track 201 and preventing it from bending under stress. It should be noted that the driving ground gear, intermediate ground gear, and driven ground gears 303 are all high-precision ground gears to ensure transmission accuracy. The transmission component 302 can also be configured as other types of transmission structures, such as racks, belts, chains, etc.

[0044] Furthermore, the servo motors of the two sets of control components 3 can operate synchronously or differentially. During normal production, the two sets of servo motors operate synchronously, driving the segmented grinding spur racks 202 of the two sets of mold components 2 to move synchronously. When adjusting for misalignment, the two sets of servo motors operate differentially, forming a speed deviation to correct the misalignment error. When adjusting for misalignment, one of the servo motors is generally used as the standard, and the speed deviation of the other servo motor is adjusted.

[0045] In some embodiments, the movable platform 4 is a rigid steel structure platform with multiple tracks on its upper surface that slide with the support 1. These tracks are arranged perpendicular to the straight sections of the two supports 1 to ensure the straightness of the sliding of the support 1. The electric screw assembly 5 includes a servo screw motor and a bidirectional ball screw. The two ends of the bidirectional ball screw are respectively connected to the two supports through screw-nut pairs. The output shaft of the servo screw motor is coaxially and fixedly connected to one end of the bidirectional ball screw. When the servo screw motor is running, it drives the bidirectional ball screw to rotate, thereby driving the two supports to move closer or further apart in a straight line along the tracks of the movable platform 4, realizing the adjustment of the distance between the two sets of mold assemblies 2, and adapting to the production of double-wall corrugated pipes of different diameters, such as DN300, DN500, and DN800.

[0046] In some implementations, the detection device is used to collect misalignment error data in real time and transmit it to the controller of the servo motor. It includes a displacement sensor and a mold alignment detection unit. The displacement sensor employs a high-precision multi-turn absolute encoder. Each servo motor has a built-in high-resolution multi-turn absolute encoder, which provides real-time feedback on the precise angular position of the motor. Combined with the known gear pitch circle diameter, the controller can accurately calculate the theoretical linear travel of the gear rolling on the fixed rack, which is the basis for position control. The mold alignment detection unit is located at the mold exit and includes a laser scanner and an industrial vision camera. The laser scanner performs a laser scan on the mold parting line of the formed corrugated pipe, and the industrial vision camera captures the parting line in real time. The two work together to directly detect misalignment on the corrugated pipe parting line. The detection data is cross-validated with the data collected by the displacement sensor, avoiding errors from a single detection method and improving the accuracy of misalignment detection. If the difference between the detection results of the mold alignment detection unit and the displacement sensor is within the allowable error range, the detection result of the mold alignment detection unit shall prevail; if the difference between the detection results of the mold alignment detection unit and the displacement sensor is outside the allowable error range, the final detection result shall be obtained by weighted averaging, wherein the weighting coefficient of the mold alignment detection unit is greater than the weighting coefficient of the displacement sensor, for example, the former is 0.7 and the latter is 0.3. Example 2

[0047] Currently, the industry's approach to adjusting misalignment issues in double-wall corrugated pipe forming dies is still primarily based on traditional manual adjustments during shutdown. During production line operation, when operators discover misalignment defects in the pipes, they must first stop the entire production line, then enter the equipment and approach the high-speed moving forming components. They manually measure to determine the amount of misalignment, then loosen the locking mechanism of the die platform and manually adjust its position based on experience. After adjustment, they re-lock the platform and restart for trial production. If misalignment persists, the above shutdown, adjustment, and trial production process must be repeated.

[0048] This traditional adjustment method has several technical drawbacks. First, frequent production line shutdowns severely disrupt continuous production, with each adjustment taking anywhere from 20-30 minutes to several hours, significantly reducing overall equipment operating efficiency. This is particularly pronounced in 24-hour continuous production scenarios. Second, manual adjustment relies on the operator's experience and skills, making precise digital adjustments impossible. Poor adjustment accuracy and difficulty in ensuring mold alignment consistency can lead to persistent hidden errors after adjustment, resulting in inconsistent product quality. Third, the adjustment process requires operators to enter the equipment and approach the moving parts. The production line has several drawbacks. First, it poses a high risk of mechanical injury during piecework operations. Second, the manual unlocking and platform pushing operations are physically demanding. Third, during the period from the discovery of the misalignment defect to the completion of the shutdown adjustment, the production line will continuously produce defective products, resulting in a large amount of raw material and energy waste and increasing production costs. Fourth, because it is impossible to correct minor misalignments in a timely manner during production, the equipment will operate in a state of mold misalignment for a long time, which will aggravate abnormal wear of the mold and transmission mechanism, increase equipment maintenance costs and failure rate, and the lack of recording and analysis of adjustment data makes it difficult to trace the cause of the misalignment, which is not conducive to preventive maintenance and process optimization.

[0049] To address the aforementioned issues, based on the online misalignment adjustment system for double-wall corrugated pipes provided in Embodiment 1, Embodiment 2 further provides an online misalignment adjustment method for double-wall corrugated pipes. This method is based on the core concept of detection-graded quantitative adjustment-trend prediction compensation-data storage matching, avoiding fuzzy control logic, and achieving accurate, efficient, and intelligent online correction of misalignment errors, fully adapting to the actual implementation needs of industrial control. (Reference) Figure 4 As shown, the method includes the following steps: Step S1: Pre-setting parameters.

[0050] All parameters are preset through the system's human-computer interaction interface. All parameters are quantitatively defined and can be directly retrieved and executed by the central controller. Set a preset range for the misalignment error: for example, ±0.02mm, as the adjustment trigger threshold (if it exceeds the threshold, online adjustment will be started) and the adjustment completion threshold (if it falls within the threshold, the adjustment will be considered complete). Classify misalignment error levels and match drive component parameters: Based on the error value, it is divided into three levels: mild, moderate, and severe. Each level is matched with a unique speed deviation gradient and adjustment rate, specifically: Slight error: 0.02mm < |error| ≤ 0.05mm, speed deviation gradient 0.05rad / s, adjustment rate 0.1mm / s (precise fine adjustment, anti-overshoot); Medium error: 0.05mm < |error| ≤ 0.08mm, speed deviation gradient 0.1rad / s, adjustment rate 0.3mm / s (stable at medium speed, balancing efficiency and accuracy); Severe error: 0.08mm < |error|, using two-stage parameters (fast coarse adjustment + low-speed fine adjustment), coarse adjustment: speed deviation gradient 0.15rad / s, adjustment rate 0.5mm / s, fine adjustment: consistent with the parameters for slight error; Set an adjustment switching threshold, for example, ±0.04mm: This threshold is greater than the preset range of ±0.02mm and is within the minor error range. It serves as the switching node for coarse / fine adjustment of severe error, and also as the unified trigger node for speed deviation gradient and adjustment rate downgrade in all error level adjustments. It is the core parameter connecting the preset range and graded adjustment.

[0051] Step S2: Real-time detection and fusion of misplacement error.

[0052] After the system enters normal continuous production mode, the detection device continuously collects data related to mis-sprouting, and uses a dual-detection data fusion calibration method to ensure data accuracy: The displacement sensor collects the relative position data of the segmented grinding straight tooth rack 202 of the two sets of mold components 2 in real time, with a resolution of 0.01mm; the mold alignment detection unit detects the misalignment data of the mold parting line of the formed bellows at the mold exit in real time through a laser scanner and an industrial vision camera; the central controller performs fusion calibration on the above two sets of data to eliminate the system error of a single detection method, obtains an accurate real-time misalignment error value, and feeds the data back to the control module in real time.

[0053] Step S3: Adjust the trigger quantization judgment.

[0054] The central controller will quantify and compare the real-time misalignment error value after integration and calibration with the preset misalignment error range of ±0.02mm to make a clear judgment: If the real-time misalignment error value is ≤0.02mm, it is determined that no adjustment is needed. The system maintains a pure synchronous operation mode, and the two sets of drive components 301 operate synchronously and uniformly, driving the segmented grinding straight rack 202 to move synchronously. If the real-time crop misalignment error value is greater than 0.02 mm, online crop misalignment adjustment is initiated. This real-time crop misalignment error value is used as the target adjustment amount, and the process proceeds to step S4, the graded and quantitative adjustment process.

[0055] Step S4: Graded and quantitative adjustment.

[0056] The central controller performs numerical analysis on the target adjustment amount to determine its error level, automatically retrieves the control parameters of the drive components matching that level, and performs differentiated speed control on the drive components 301 of the two sets of control components 3. This causes the segmented grinding spur racks 202 of the two sets of mold components 2 to produce corresponding movement speed deviations, achieving targeted correction of misalignment errors. All adjustment nodes are triggered by data quantification from the detection device, with the adjustment switching threshold of ±0.04mm as the core linkage point. The specific control rules are as follows: Severe error adjustment: The controller first retrieves the coarse adjustment parameters to control the differential operation of the drive component 301, completing the rapid correction of most of the misalignment errors; when the detection device detects that the misalignment error value drops to the adjustment switching threshold ±0.04mm, the controller automatically switches to the fine adjustment parameters to continue adjustment, avoiding the risk of overshoot caused by rapid adjustment of large deviations; Medium error adjustment: The controller directly retrieves the medium speed matching parameters to control the differential operation of the drive unit 301, and smoothly completes the misalignment error correction in one go without the need for segmented parameter switching; Slight error adjustment: The controller directly retrieves the low-speed matching parameters to control the differential operation of the drive component 301, making precise fine adjustments throughout the process and eliminating the possibility of overshoot from the root. Unified downgrading rule: For all error levels of light, medium and heavy, when the detection device detects that the |misalignment error value| drops to the adjustment switching threshold of ±0.04mm, the controller automatically performs a step-by-step downgrading operation on the drive component 301 (the speed deviation gradient and adjustment rate are downgraded by 30% each time), so as to achieve smooth convergence of misalignment error until the error falls into the preset range of ±0.02mm.

[0057] Step S5: Trend prediction and reverse compensation correction.

[0058] Throughout the entire process of hierarchical and quantitative adjustment, the central controller performs data acquisition and model calculations in millisecond-level control cycles to achieve proactive predictive control, completely eliminating overshoot problems at the control level. The controller collects three sets of core data in real time: real-time position data of the two sets of segmented grinding spur racks 202, speed / torque operating parameters of the drive component 301, and real-time misalignment error detection data from the detection device. Based on the above data, a real-time data model for the adjustment process is constructed. The model is used to quantitatively predict the trend of misalignment error in the next control cycle. If the model predicts that the misalignment error in the next control cycle will overshoot to a preset range of ±0.02mm, the controller immediately performs reverse compensation correction on the speed deviation of the drive component 301. The compensation amount is 1.2 times the predicted overshoot value, and the drive parameters are corrected in real time to ensure that the error always converges towards the target threshold.

[0059] Step S6: Adjustment completion judgment and operation mode reset.

[0060] The central controller continuously collects the misalignment error value through the detection device and adopts a multi-cycle stable judgment rule to avoid misjudgment caused by single data fluctuations. Specifically, when the misalignment error values ​​collected by the detection device for three consecutive millisecond-level control cycles all meet the preset range of |error value|≤0.02mm, the controller determines that the online adjustment of the misalignment is completed. After the judgment is completed, the controller immediately sends a synchronization command to the two sets of drive components 301, controls the drive components 301 to resume the pure synchronous operation mode, and drives the segmented grinding straight tooth racks 202 of the two sets of mold components 2 to move synchronously and uniformly along the circular track 201. The system quickly returns to the normal continuous production state of double-wall corrugated pipes without any transition time after adjustment.

[0061] Step S7: Full data storage and intelligent matching and retrieval.

[0062] After the misalignment adjustment is completed, the controller automatically encrypts and stores all adjustment data and enables rapid matching and parameter adjustment for subsequent similar errors, improving the system's intelligent adaptive capability. The controller stores all core parameters of this adjustment in the misalignment adjustment history database, including: target adjustment amount, error level, matching speed deviation gradient / adjustment rate, adjustment switching threshold trigger time, coarse / fine adjustment switching node, downshifting times, total adjustment time, and final stable error value. When the detection device detects the same or similar misalignment error again (the similarity can be taken as an error difference ≤0.01mm), the controller directly retrieves the fully matching control parameters from the history database to quickly and accurately control the drive component 301 without re-classifying and matching parameters, significantly shortening the adjustment time for subsequent similar errors.

[0063] The online misalignment adjustment method for double-walled corrugated pipes in this embodiment uses a graded quantitative adjustment strategy to achieve rapid coarse adjustment and correction of severe errors, as well as low-speed fine adjustment to improve accuracy. For minor errors, it provides precise low-speed overshoot prevention throughout the process, and for moderate errors, it provides stable adjustment that balances efficiency and accuracy. By combining trend prediction and reverse compensation correction, it completely eliminates overshoot problems at the control level and uses a historical database to achieve one-click matching and parameter adjustment for similar errors. Actual production verification shows that this method can control the adjustment time for minor errors to 1-2 seconds, for moderate errors to 2-3 seconds, and for severe errors to 3-5 seconds. The adjustment accuracy of all errors is stably controlled within the preset range of ±0.02mm. The scrap rate of double-wall corrugated pipes due to misalignment has been reduced from the traditional 8% to below 0.3%, and the overall operating efficiency of the equipment has been improved by more than 35%, significantly reducing raw material loss and manual intervention costs. At the same time, it avoids abnormal wear of molds and transmission mechanisms caused by the accumulation of minor errors, extending the service life of the equipment. Moreover, all adjustment data is traceable, providing complete data support for preventive maintenance and process optimization, and is fully adapted to the industry needs of 24-hour continuous production.

[0064] The above description is only a preferred embodiment of this application, and the above data is only for illustrative purposes and is not intended to limit this application. Any modifications, equivalent substitutions and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. An online staggered adjustment system for double-walled corrugated pipes, characterized in that, It includes two supports (1) arranged opposite to each other, each of the supports (1) is provided with a set of mold assembly (2), and each set of mold assembly (2) is connected to a set of control assembly (3); The mold assembly (2) includes an annular track (201) disposed on the bracket (1) and a plurality of segmented grinding straight racks (202) slidably disposed along the annular track (201); the side of the annular track (201) near the other bracket (1) is configured as a straight segment; The control component (3) includes a drive component (301) mounted on the bracket (1) and a transmission component (302) mounted at the output end of the drive component (301). The transmission component (302) meshes with the segmented grinding spur rack (202). The drive component (301) is used to control the moving speed of the segmented grinding spur rack (202) so that the segmented grinding spur racks (202) of the two sets of mold components (2) correspond one-to-one at the straight section and the misalignment error is kept within a preset range.

2. The online staggered adjustment system for double-wall corrugated pipes according to claim 1, characterized in that, The annular track (201) includes two tracks arranged symmetrically at the top and bottom. The segmented grinding straight rack (202) is provided with sliding blocks (2021) at both the top and bottom ends. The segmented grinding straight rack (202) is slidably connected to the upper and lower tracks respectively through the sliding blocks (2021) at the top and bottom ends.

3. The online staggered adjustment system for double-wall corrugated pipes according to claim 2, characterized in that, The upper and lower tracks of the annular track (201) are each provided with two inner and two outer grooves (2011). The upper and lower ends of the segmented grinding straight toothed rack (202) are each provided with two sliding blocks (2021) and distributed diagonally, so that each sliding block (2021) is located in a groove (2011).

4. The online staggered adjustment system for double-wall corrugated pipes according to claim 1, characterized in that, The drive component (301) includes a servo motor and a reducer connected to the servo motor. The transmission component (302) includes at least two meshing gears, one of which is mounted on the output shaft of the reducer, and the other gear meshes with the segmented grinding spur rack (202) and is rotatably mounted on the bracket (1).

5. The online staggered adjustment system for double-wall corrugated pipes according to claim 4, characterized in that, The transmission component (302) also includes a plurality of driven grinding gears (303) rotatably mounted on the bracket (1). The driven grinding gears (303) are distributed along the inner side of the annular track (201), and each driven grinding gear (303) meshes with the segmented grinding spur rack (202).

6. The online staggered adjustment system for double-wall corrugated pipes according to any one of claims 1-5, characterized in that, The bracket (1) is slidably mounted on the movable platform (4). The two brackets (1) are connected by an electric screw assembly (5), which is used to drive the two brackets (1) to move closer or further apart.

7. The online staggered adjustment system for double-wall corrugated pipes according to any one of claims 1-5, characterized in that, It also includes a detection device, which includes a displacement sensor and / or a mold alignment detection unit. The displacement sensor includes an absolute encoder connected to the control component (3), and the mold alignment detection unit includes a laser scanner and / or a vision inspection system located at the mold exit.

8. A method for online staggered adjustment of double-wall corrugated pipes, applied to the online staggered adjustment system for double-wall corrugated pipes as described in claim 7, characterized in that, include: The misplanting error is measured by a detection device. If the misplanting error exceeds the preset range, the misplanting error is used as the target adjustment amount. The two sets of drive components (301) are controlled separately according to the target adjustment amount, so that the two sets of drive components (301) produce speed deviation, so as to reduce the misalignment error; The misalignment error is measured again by the detection device. If the misalignment error falls within the preset range, the adjustment is completed, and the two sets of drive components (301) are controlled to return to pure synchronous mode.

9. The online staggered adjustment method for double-wall corrugated pipes according to claim 8, characterized in that, The method of controlling the two sets of drive components (301) separately according to the target adjustment amount to generate speed deviation between the two sets of drive components (301) in order to reduce the misalignment error specifically includes: The target adjustment amount is analyzed in a graded manner. According to the magnitude of the misalignment error, it is divided into mild, moderate and severe error levels. Different error levels are matched with preset speed deviation gradient and adjustment rate of drive component (301). Among them, severe error is matched with two-stage parameters of maximum speed deviation gradient and high-speed coarse adjustment rate, minimum speed deviation gradient and low-speed fine adjustment rate, moderate error is matched with medium speed deviation gradient and medium speed adjustment rate, and mild error is matched with minimum speed deviation gradient and low speed adjustment rate. At the same time, a preset adjustment switching threshold is set. The adjustment switching threshold is greater than the preset range and is within the mild error range. It serves as the switching node between coarse and fine adjustment for severe errors, as well as the unified trigger node for speed deviation gradient and adjustment rate downgrade in all error level adjustments. For severe errors, the rotation speed of the two sets of drive components (301) is first controlled according to the maximum speed deviation gradient and the high-speed coarse adjustment rate to complete the coarse adjustment. When the detection device detects that the error has dropped to the adjustment switching threshold, the minimum speed deviation gradient and the low-speed fine adjustment rate are switched to continue the adjustment. For moderate errors, the rotation speed of the drive components (301) is directly controlled according to the matched speed deviation gradient and adjustment rate. For slight errors, precise fine adjustment is performed directly according to the matched speed deviation gradient and adjustment rate. When the detection device detects that the misalignment error has dropped to the adjustment switching threshold, it gradually reduces the speed deviation gradient of the drive unit (301) and decreases the adjustment rate until the misalignment error falls into the preset range.

10. The online staggered adjustment method for double-wall corrugated pipes according to claim 9, characterized in that, Also includes: During the adjustment process, the position data of the segmented grinding straight tooth rack (202) of the two sets of mold components (2) on the straight section of the circular track (201), the running parameters of the drive component (301) and the misalignment error detection data of the detection device are collected in real time to construct a real-time data model of the adjustment process. The data model is used to predict the trend of the cropping error. If the cropping error is predicted to overshoot to outside the preset range, the speed deviation of the drive component (301) is corrected in advance by reverse compensation. After the adjustment is completed, the target adjustment amount, error level, matching speed deviation gradient and adjustment rate, adjustment switching threshold trigger time, adjustment duration and final error value are stored to form a historical database of mis-cropping adjustment. When the detection device detects the same or similar mis-cropping error again, it directly retrieves the matching parameters in the historical database to control the drive unit (301).

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