Flexible adjustment method for a single-wall bellows slitting machine and related apparatus

Abstract

The application provides a flexible adjustment method of a single-wall corrugated pipe slotting machine and related equipment, and relates to the technical field of automatic control. The method comprises the following steps: first, scanning a batch code to obtain basic entity parameters of a single-wall corrugated pipe to be processed, comparing the basic entity parameters with preset standard entity parameter intervals, judging whether to start tolerance boundary deduction, and then determining a tolerance boundary containing an upper and lower limit angle threshold; second, detecting an angle value of a pipe passing support in real time through an angle potential sensor, comparing the angle value with the tolerance boundary, judging whether the pipe material is in a tight, relaxed or normal state, and finally adjusting a slotting traction speed according to the comparison result according to the deviation size to ensure stable processing. The method realizes adaptive synchronization of the slotting traction speed and the pipe production line speed, and improves the slotting depth uniformity and the wave distance precision.

Description

Technical Field

[0001] This application relates to the field of automatic control technology, and in particular to a flexible adjustment method and related equipment for a single-wall corrugated pipe grooving machine. Background Technology

[0002] During the molding and processing of plastic single-wall corrugated pipes, a grooving machine is often used to groove the outer wall of the pipe to meet the needs of subsequent assembly, flow guidance, or structural reinforcement. The grooving machine typically uses a servo motor to drive a rotating spiral cutter head. To ensure uniform grooving depth and stable corrugation, the grooving traction speed must be synchronized with the online production speed of the pipe. This is a key process in the continuous and automated production of plastic pipes.

[0003] Existing plastic corrugated pipe grooving machines mostly employ a floating limit switch combined with position detection adjustment method. Upstream and downstream floating limit devices are installed on the frame, and position sensors detect the displacement of the grooving device along the production direction. The controller adjusts the servo motor speed based on the position signal, thereby regulating the grooving speed. This solution relies on the pipe material pushing the floating machine to generate position changes, using this as the primary basis for speed adjustment.

[0004] The above adjustment method has significant drawbacks when applied to single-wall corrugated pipes: single-wall corrugated pipes have thin walls, are prone to elastic deformation, and have poor corrugation stability. During production, the pipes are prone to loosening or tightening, leading to unstable thrust from the pipes onto the floating machine. Changes in the machine's position cannot accurately reflect the pipe tension and conveying status, resulting in adjustment lag and inaccurate response. Ultimately, this can cause uneven grooving depth and excessive corrugation deviation, and in severe cases, it can lead to pipe scrapping, affecting grooving quality and production efficiency. Summary of the Invention

[0005] This application provides a flexible adjustment method and related equipment for a single-wall corrugated pipe grooving machine, which is used to achieve automated and precise control of stable grooving tension and uniform grooving quality.

[0006] In a first aspect, this application provides a flexible adjustment method for a single-wall corrugated pipe grooving machine. The method includes: obtaining the basic physical parameters of the single-wall corrugated pipe to be processed by scanning the batch barcode; comparing the basic physical parameters with a preset standard physical parameter range to determine whether to activate the tolerance boundary deduction; determining the tolerance boundary of the single-wall corrugated pipe to be processed, wherein the tolerance boundary is an interval including an upper limit angle threshold and a lower limit angle threshold; detecting the angle value of the pipe support in real time by using an angle potential sensor; comparing the angle value with the tolerance boundary to obtain a comparison result; and adjusting the grooving traction speed based on the comparison result.

[0007] By adopting the above technical solution, the basic physical parameters specific to single-wall corrugated pipes are quickly retrieved by scanning batch barcodes, enabling rapid and accurate input of pipe parameters without manual input and calibration, thus improving the efficiency and accuracy of parameter acquisition. Then, by comparing parameters with standard ranges, the tolerance boundary is determined to extrapolate start-stop functionality, adapting to the differences in physical properties between different batches of pipes. Angle potential sensors are used to collect the angle values ​​of the pipe support in real time, using the angle range as the basis for determining pipe tension and conveying status, replacing the traditional floating machine displacement detection method. Based on the angle comparison results, the grooving traction speed is dynamically adjusted to achieve adaptive synchronization between the grooving traction speed and the pipe production line speed, avoiding detection distortion problems caused by the easy deformation and unstable wave pitch of single-wall corrugated pipes, ensuring the uniformity of grooving depth and wave pitch accuracy from the source.

[0008] In conjunction with some embodiments of the first aspect, in some embodiments, the step of comparing the basic entity parameters with a preset standard entity parameter range to determine whether to enable tolerance boundary deduction specifically includes: extracting tolerance feature values ​​from the basic entity parameters, the tolerance feature values ​​including at least pipe wall thickness and material hardness; determining whether the tolerance feature values ​​are within the standard entity parameter range; if they are within the standard entity parameter range, then the tolerance boundary deduction is not enabled, and the preset standard tolerance boundary corresponding to the standard entity parameter range is determined as the tolerance boundary; if they are not within the standard entity parameter range, then the tolerance boundary deduction is enabled to determine the tolerance boundary.

[0009] By adopting the above technical solution, core tolerance characteristic values ​​such as pipe wall thickness and material hardness are extracted. These values ​​directly determine the elastic deformation capacity and tension response characteristics of single-wall corrugated pipes, and are key indicators affecting the synchronous control of slotting. By comparing the characteristic values ​​with standard entity parameter ranges, two types of working conditions are divided: conventional pipes and deviated pipes. Conventional pipes directly adopt the preset standard tolerance boundary, simplifying the control logic and reducing the computational load. For non-standard pipes exceeding the range, tolerance boundary deduction is automatically initiated to achieve differentiated boundary adaptation, avoiding judgment deviations caused by using a uniform threshold to deal with differentiated pipes, and improving the compatibility and adaptability of the control scheme for single-wall corrugated pipes of different specifications.

[0010] In conjunction with some embodiments of the first aspect, in some embodiments, if the feature is not within the standard entity parameter range, the step of initiating the tolerance boundary deduction to determine the tolerance boundary specifically includes: calculating the difference between the tolerance feature value and the endpoint value of the standard entity parameter range to obtain the feature offset; determining the target boundary correction coefficient corresponding to the feature offset based on a preset tolerance offset mapping table, wherein the tolerance offset mapping table records the correspondence between different feature offsets and boundary correction coefficients; and correcting the preset standard tolerance boundary based on the target boundary correction coefficient to obtain the tolerance boundary.

[0011] By employing the above technical solution, the deviation between the actual pipe parameters and standard parameters is quantified by calculating the characteristic offset between the tolerance feature value and the endpoint value of the standard interval, providing accurate data for boundary correction. Relying on a preset tolerance offset mapping table to match the corresponding boundary correction coefficient, complex real-time modeling calculations are unnecessary; coefficient matching can be quickly completed using a preset data table, improving response speed. The standard tolerance boundary is calibrated and corrected using the target boundary correction coefficient, ensuring that the corrected tolerance boundary conforms to the actual deformation and tension characteristics of the current pipe, solving the boundary threshold adaptation failure problem caused by the deviation of the physical properties of single-walled thin pipes, and ensuring the accuracy of angle detection and judgment.

[0012] In conjunction with some embodiments of the first aspect, in some embodiments, the step of comparing the angle value with the tolerance boundary to obtain a comparison result specifically includes: obtaining an upper angle threshold and a lower angle threshold in the tolerance boundary; if the angle value is greater than the upper angle threshold, then determining that the current state of the single-wall corrugated pipe to be processed is a taut state; if the angle value is less than the lower angle threshold, then determining that the current state of the single-wall corrugated pipe to be processed is a relaxed state; if the angle value is between the upper angle threshold and the lower angle threshold, then determining that the current state of the single-wall corrugated pipe to be processed is a normal state; and determining the current state as the comparison result.

[0013] By adopting the above technical solution, a standardized tolerance range is constructed using upper and lower angle thresholds. The real-time angle value of the pipe support is incorporated into the range comparison logic, transforming the abstract three operating conditions of pipe tension, relaxation, and normal operation into quantifiable angle values. Utilizing the physical characteristic that the pipe support's angle shifts with pipe tension changes, the angle change is precisely correlated with the pipe's transport status, replacing traditional thrust displacement detection methods and avoiding thrust fluctuation interference caused by the elastic deformation of thin pipes. This achieves real-time, lag-free identification of the pipe's operating status, providing a reliable basis for subsequent precise adjustment of traction speed.

[0014] In conjunction with some embodiments of the first aspect, in some embodiments, the step of adjusting the grooving traction speed based on the comparison result specifically includes: if the comparison result is in a tense state, calculating the difference between the angle value and the upper limit angle threshold to obtain a first instantaneous deviation; determining the traction speed reduction amount based on the first instantaneous deviation to reduce the grooving traction speed; if the comparison result is in a relaxed state, calculating the difference between the lower limit angle threshold and the angle value to obtain a second instantaneous deviation; determining the traction speed increase amount based on the second instantaneous deviation to increase the grooving traction speed; if the comparison result is in a normal state, maintaining the current grooving traction speed unchanged.

[0015] By adopting the above technical solution, differentiated speed regulation logic is set for three working conditions: tight, relaxed, and normal, which conforms to the actual production fluctuation law of single-wall corrugated pipes. The instantaneous deviation between the angle threshold and the actual angle value is calculated separately to quantify the degree of deviation of the pipe from the normal state, so that the speed adjustment has a precise quantitative basis, rather than a rough gear adjustment. The traction speed is increased or decreased according to the instantaneous deviation: the speed is reduced when tight, increased when relaxed, and stabilized when normal, forming a two-way adaptive speed regulation mechanism. This quickly offsets the loose or tight working conditions of the pipe, maintains constant pipe conveying tension, and eliminates the problem of groove synchronization misalignment.

[0016] In conjunction with some embodiments of the first aspect, some embodiments further include a method for calculating the change in traction speed, the method comprising: using a proportional-integral-differential algorithm to calculate the first instantaneous deviation or the second instantaneous deviation to obtain the decrease in traction speed or the increase in traction speed.

[0017] By adopting the above technical solution, a proportional-integral-derivative (PID) algorithm is used to calculate instantaneous deviations. This approach combines the advantages of immediate proportional response, integral elimination of steady-state error, and derivative prediction of fluctuations, making it suitable for the operating conditions of single-wall corrugated pipes where tension is prone to sudden changes and elastic deformation. Compared to fixed-coefficient speed regulation, the PID algorithm can dynamically fit the trend of deviation changes, accurately calculate the increase or decrease in traction speed, and avoid problems such as overshoot, oscillation, or under-regulation in speed adjustment. It smoothly corrects the slotted traction speed, reduces the pulling and squeezing of the pipe caused by sudden speed changes, prevents deformation and damage to thin pipes, and simultaneously improves the stability and accuracy of speed synchronization control.

[0018] In conjunction with some embodiments of the first aspect, in some embodiments: the frame is further provided with an angle potential sensor and a pipe support, the pipe support being used to support the plastic corrugated pipe; the angle potential sensor is connected to the pipe support and is used to detect the angle change of the pipe support; the controller is electrically connected to the angle potential sensor and is used to adjust the grooving traction speed according to the signal of the angle potential sensor.

[0019] By adopting the above technical solution, the beneficial effects to be supplemented are derived.

[0020] Secondly, this application provides a single-wall corrugated pipe grooving machine for implementing the method described in the first aspect. The single-wall corrugated pipe grooving machine includes a frame, a plastic corrugated pipe grooving device, a position sensor, and a controller. The grooving device includes a servo motor and a spiral cutter head assembly. The controller is electrically connected to the position sensor and the servo motor. The frame is further equipped with an angle potential sensor and a pipe-passing support. The pipe-passing support is used to support the plastic corrugated pipe. The angle potential sensor is connected to the pipe-passing support and is used to detect changes in the angle of the pipe-passing support. The controller is electrically connected to the angle potential sensor and is used to adjust the grooving traction speed according to the signal from the angle potential sensor.

[0021] Thirdly, this application provides a server comprising: one or more processors and a memory; the memory is coupled to the one or more processors and is used to store computer program code including computer instructions, wherein the one or more processors invoke the computer instructions to cause the server to perform the methods described in the first aspect and any possible implementation thereof.

[0022] Fourthly, this application provides a computer-readable storage medium including instructions that, when executed on a server, cause the server to perform the method described in the first aspect and any possible implementation thereof.

[0023] Fifthly, this application provides a computer program product, including a computer program that, when run on a server, causes the server to perform the method described in the first aspect and any possible implementation thereof.

[0024] One or more technical solutions provided in the embodiments of this application have at least the following technical effects or advantages:

[0025] 1. By employing a flexible synchronous adjustment technology that uses barcode scanning to retrieve basic pipe parameters, angle potential sensors to collect support angles in real time, and speed adjustment based on tolerance boundary range comparison, the technology effectively solves the problems of existing technologies that rely on floating machine displacement detection, are easily deformed by thin-walled single-wall corrugated pipes, have unstable wave pitch, and suffer from detection distortion and inaccurate adjustment response due to thrust fluctuation interference. This achieves adaptive and precise synchronization between the grooving traction speed and the pipe production line speed, stably controls the uniformity of grooving depth and wave pitch accuracy, reduces pipe scrap, and improves production stability and processing quality.

[0026] 2. By employing the technical means of calculating the pipe feature offset, matching the correction coefficient based on the preset offset mapping relationship table, and adaptively correcting the standard tolerance boundary, the problem of inaccurate angle state judgment caused by the use of a unified judgment threshold in the existing technology, which cannot adapt to the material property deviation of different batches of single-wall corrugated pipes, is effectively solved. This achieves the technical effect of dynamically adapting and fitting the tolerance boundary with the actual parameters of the pipe, improving the accuracy of angle detection and working condition judgment, and enhancing the compatibility and adaptability of slotting speed control with different pipe specifications.

[0027] 3. By adopting a technology that classifies pipes into three states—tight, loose, and normal—and quantifies and matches the increase or decrease in traction speed based on instantaneous deviation, the technology effectively solves the problems of existing technologies having a coarse speed regulation logic, being unable to accurately match the real-time tension of the pipes, and easily causing uneven grooving depth and excessive wave pitch deviation. This achieves the technical effect of real-time offsetting of pipe looseness and tightness fluctuations, maintaining constant conveying tension, ensuring continuous and stable grooving operations, and significantly improving synchronous matching accuracy. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of a related technical structure of a single-wall corrugated pipe grooving machine in an embodiment of this application;

[0029] Figure 2 This is a flowchart illustrating the flexible adjustment method of the single-wall corrugated pipe grooving machine in an embodiment of this application;

[0030] Figure 3 This is a schematic diagram of the physical device structure of a server in an embodiment of this application. Detailed Implementation

[0031] The terminology used in the following embodiments of this application is for the purpose of describing particular embodiments only and is not intended to be limiting of this application. The singular expressions “a,” “an,” “the,” “the,” “the,” and “this” are intended to include the plural expressions as well, unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used in this application refers to and includes any or all possible combinations of one or more of the listed items.

[0032] Hereinafter, the terms "first" and "second" are used for descriptive purposes only and should not be construed as implying or suggesting relative importance or implicitly indicating the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature, and in the description of the embodiments of this application, unless otherwise stated, "multiple" means two or more.

[0033] To facilitate understanding, the relevant technologies for this implementation method will be introduced below. Please refer to... Figure 1 This is a schematic diagram of a related technical structure of a single-wall corrugated pipe grooving machine in an embodiment of this application.

[0034] exist Figure 1The plastic corrugated pipe grooving machine of this related technology mainly includes the following structure: 1 is the frame, 2 is the plastic corrugated pipe grooving device, 201 is the mounting plate, 4 is the spiral cutter head, 5 is the cutter, 7 is the linear guide rail assembly, 8 is the upstream floating limit device, 9 is the downstream floating limit device, S is the production direction, H is the plastic corrugated pipe, and E is the view direction mark. For a detailed description of the specific components of the single-wall corrugated pipe grooving machine, please refer to the structure disclosed in CN221291490U. This application mainly provides a detailed description of the improved control logic; other components are not described here.

[0035] In this related technology, the grooving device 2 can slide on the frame 1 along the production direction S via the linear guide rail assembly 7. A position sensor on the frame 1 detects the displacement of the grooving device 2, and floating limit devices are set upstream and downstream to elastically limit the mounting plate 201. During operation, when the rotational speed of the spiral cutter head 4 does not match the pipe's moving speed, the pipe pushes the mounting plate 201 to deviate along the production direction. The controller adjusts the servo motor speed based on the position sensor signal to achieve speed matching. However, when this solution is applied to single-wall corrugated pipes, due to the thin wall, poor rigidity, and insufficient corrugation stability of the single-wall pipe, the thrust of the pipe on the mounting plate 201 is unstable. Changes in the machine position cannot accurately reflect the pipe's conveying status, leading to adjustment lag and inaccurate response. Ultimately, this results in uneven grooving depth and excessive corrugation deviation, and in severe cases, pipe scrapping.

[0036] The method provided in this implementation is described below in conjunction with the aforementioned technical structures. Please refer to [link / reference]. Figure 2 This is a flowchart illustrating a flexible adjustment method for a single-wall corrugated pipe grooving machine in an embodiment of this application.

[0037] S101. Obtain the basic physical parameters of the single-wall corrugated pipe to be processed by scanning the batch barcode;

[0038] Among them, the batch barcode refers to a one-dimensional or two-dimensional barcode marked on the outer packaging or tray of the single-wall corrugated pipe to be processed, which contains the unique production information of the batch of pipes. It is used to indicate the production batch, specifications, physical properties and other information of the pipe. The basic entity parameters refer to the set of parameters related to the physical characteristics of the single-wall corrugated pipe to be processed, which are stored in the server or controller. They are the input basis for subsequent control logic and are used to represent the inherent properties of the pipe.

[0039] This step, performed during the pipe loading stage before the slotting operation begins, is a crucial step in equipment initialization. After the operator installs the single-wall corrugated pipe coil to be processed onto the equipment, the batch barcode must be aligned with the barcode scanner on the equipment. The scanner reads the barcode and transmits the data to the server. Based on the batch number contained in the barcode, the server retrieves the complete basic physical parameters of that batch of pipe from a pre-set pipe parameter database. These parameters include, but are not limited to, the nominal diameter, wall thickness, material, hardness, elastic modulus, wave pitch design value, and standard tolerance range. The server stores the retrieved basic physical parameters in the controller's cache, providing data support for subsequent tolerance boundary calculations and control logic. The entire process eliminates the need for manual parameter input, avoiding human error, and also enables rapid switching of parameters between different batches of pipe, improving production preparation efficiency.

[0040] S102. Compare the basic entity parameters with the preset standard entity parameter range to determine whether to enable tolerance boundary simulation.

[0041] Among them, tolerance boundary simulation refers to the process by which the server dynamically adjusts the angle control threshold based on the actual physical properties of the pipe when the pipe parameters exceed the standard range, in order to adapt to the tension response characteristics of non-standard pipes.

[0042] This step is automatically triggered by the server immediately after completing the batch barcode scanning and successfully obtaining the complete basic entity parameters of the single-wall corrugated pipe to be processed. It is a key pre-process in the entire flexible adjustment method for parameter determination and control mode selection. It directly determines the setting method of the subsequent angle threshold, and thus affects the accuracy and stability of the entire slotting traction speed adjustment. It is one of the core links to adapt to single-wall corrugated pipes with different physical properties and solve the problem of poor adaptability of traditional adjustment methods. When the server executes this step, it first initiates a preset parameter extraction program. From the complete set of basic entity parameters already acquired, it accurately filters and extracts preset tolerance feature values. Among these, pipe wall thickness and material hardness are two core parameters that must be extracted. This is because pipe wall thickness directly determines the elastic deformation resistance of the single-wall corrugated pipe. The thinner the wall, the easier it is for the pipe to undergo elastic deformation, and the more sensitive it is to changes in tension. Material hardness, on the other hand, determines the rigidity and deformation recovery speed of the pipe. The lower the hardness, the easier it is for the pipe to undergo tensile or bending deformation under tension. The higher the hardness, the more likely the pipe is to break or be damaged due to excessive rigidity. Together, these two factors constitute the core factors affecting the detection of pipe tension status and speed adjustment. In addition, based on actual production needs and differences in pipe specifications, the server can also simultaneously extract auxiliary tolerance feature values ​​such as elastic modulus, wave pitch tolerance, and nominal pipe diameter to further improve the accuracy of subsequent boundary determination.

[0043] After extraction, the server will immediately retrieve the pre-stored standard entity parameter range. This standard entity parameter range is formed based on the statistical analysis of the physical properties of a large number of conventional mass-produced single-wall corrugated pipes and the calibration of long-term production practice data. Each tolerance characteristic value corresponds to a specific standard range. For example, the standard range for pipe wall thickness can be set to 1.2mm-2.0mm, and the standard range for material hardness (Shore hardness) can be set to 60D-80D. Different specifications of conventional pipes correspond to different standard entity parameter ranges. The server will automatically match the corresponding standard entity parameter range based on the nominal diameter and other basic information of the current pipe to ensure the relevance and accuracy of the comparison.

[0044] Subsequently, the server will initiate a comparison calculation program, which will compare each extracted tolerance feature value with the upper and lower limits of the standard entity parameter range for the corresponding parameter, and verify whether the value falls within the corresponding standard allowable range. For example, the actual wall thickness of the current pipe will be compared with the upper and lower limits of the standard wall thickness range to determine whether the actual wall thickness is between 1.2mm and 2.0mm. The actual material hardness will be compared with the upper and lower limits of the standard hardness range to determine whether the actual hardness is between 60D and 80D. If there are multiple auxiliary tolerance feature values, they will also be compared one by one in the same way. After comparing all tolerance feature values, the server will make a comprehensive judgment on the comparison results: if all tolerance feature values ​​fall within their respective standard entity parameter ranges, the server will determine that the single-wall corrugated pipe to be processed is a conventional standard specification pipe. The elastic deformation capacity and tension response characteristics of this type of pipe are within the normal range, and there is no need to start complex boundary correction calculations. At this time, the server will directly retrieve the preset standard tolerance boundary corresponding to the standard entity parameter range. This preset standard tolerance boundary is a fixed angle threshold range formed in advance for pipes in this standard parameter range through a large number of experiments, including a clear upper limit angle threshold and a lower limit angle threshold. The server directly assigns this preset standard tolerance boundary as the tolerance boundary used for the current grooving processing. This simplifies the control logic, reduces the computational load of the server, and ensures the adjustment accuracy of conventional pipes, avoiding adjustment lag caused by excessive calculation.

[0045] If any tolerance characteristic value exceeds the upper or lower limit of the corresponding standard entity parameter range, for example, if the actual pipe wall thickness is 1.0mm, lower than the lower limit of the standard wall thickness range (1.2mm), or the actual material hardness is 55D, lower than the lower limit of the standard hardness range (60D), or the actual wall thickness is 2.2mm and the hardness is 85D, exceeding the upper limit of the corresponding standard range, the server determines that the single-wall corrugated pipe to be processed is a non-standard specification pipe with deviated physical properties. The elastic deformation capacity and tension response characteristics of such pipes differ significantly from those of conventional pipes. If the preset standard tolerance boundary is still applied, it will... This can lead to problems such as misjudgment in angle detection and inaccurate speed adjustment. Therefore, the server will immediately and automatically start the tolerance boundary deduction process. Subsequently, by calculating the feature offset, matching the target boundary correction coefficient, and correcting the standard tolerance boundary, the server will recalculate the exclusive tolerance boundary that is suitable for the current pipe material properties. This will enable differentiated threshold adaptation for single-wall corrugated pipes of different batches and properties, and solve the problems of angle misjudgment, speed adjustment lag, and poor grooving quality caused by the traditional adjustment method using a uniform standard threshold that cannot be adapted to non-standard pipe materials. This will provide accurate threshold basis for subsequent angle detection and speed adjustment.

[0046] After determining that the tolerance characteristic value of the single-wall corrugated pipe to be processed is not within the standard physical parameter range, the server can customize a tolerance boundary that is suitable for the elastic deformation capacity and tension response characteristics of the non-standard pipe material with deviated physical properties, thus solving the problem that the traditional unified threshold cannot be adapted to non-standard pipe materials, resulting in misjudgment of angle and inaccurate speed regulation.

[0047] The server first initiates the offset calculation program. For each tolerable feature value exceeding the standard entity parameter range, it calculates the difference between the value and the corresponding endpoint of the standard range to obtain the feature offset. During the calculation, the server first determines the direction of the deviation from the range. If the tolerable feature value is greater than the upper limit of the standard range, the feature offset is the difference between that value and the upper limit. If the tolerable feature value is less than the lower limit of the standard range, the feature offset is the difference between that value and the lower limit (the absolute value is taken to ensure the offset is positive for subsequent coefficient matching). For example, if the actual wall thickness of the pipe is 1.0mm, and the standard wall thickness range is 1.2mm-2.0mm, the actual wall thickness is lower than the lower limit, so the feature offset is 1.2mm-1.0mm=0.2mm; if the actual material hardness is 85D, and the standard hardness range is 60D-80D, the actual hardness is higher than the upper limit, so the feature offset is 85D-80D=5D. If multiple tolerable feature values ​​exceed the standard range, their respective feature offsets are calculated separately.

[0048] After calculation, the server immediately retrieves a pre-stored tolerance offset mapping table. This table is compiled based on extensive experimental data of non-standard pipes, combined with the adaptation rules of pipe properties and angle thresholds. The table clearly records the one-to-one correspondence between different types and sizes of feature offsets and their corresponding boundary correction coefficients. The larger the offset, the larger the correction coefficient and the greater the correction magnitude. Furthermore, corresponding mapping sub-tables are set for different tolerance feature values ​​(such as wall thickness and material hardness) to ensure the targeted matching of correction coefficients. Subsequently, the server accurately matches the corresponding target boundary correction coefficient in the corresponding mapping sub-table for each calculated feature offset. If multiple feature offsets exist, the average of the corresponding correction coefficients is taken as the final target boundary correction coefficient, taking into account the influence of various physical property parameters to ensure the rationality of the correction.

[0049] After matching is complete, the server initiates a boundary correction procedure. Based on the preset standard tolerance boundary, it uses the target boundary correction coefficient to synchronously correct the upper and lower angle thresholds of the preset standard tolerance boundary. During correction, the calculation method of "threshold × correction coefficient" is adopted. For example, if the upper angle threshold of the preset standard tolerance boundary is 15° and the lower angle threshold is 5°, and the target boundary correction coefficient is 1.2, the corrected upper angle threshold is 15° × 1.2 = 18°, and the lower angle threshold is 5° × 1.2 = 6°. If the feature offset is negative (e.g., thinner wall thickness), the correction coefficient is greater than 1, expanding the tolerance boundary range and avoiding misjudgments caused by minor deformation of the pipe. If the feature offset is positive (e.g., higher hardness), the correction coefficient can be less than 1, narrowing the tolerance boundary range and improving detection sensitivity. After the correction is completed, the server will obtain the new angle threshold range, determine it as the tolerance boundary of the single-wall corrugated pipe to be processed, and store it in the controller cache. This will serve as the core basis for subsequent angle detection, status determination, and speed adjustment, ensuring that the tolerance boundary is fully compatible with the actual physical properties of non-standard pipes. This will improve the accuracy of angle determination from the source and provide a reliable guarantee for subsequent precise speed adjustment.

[0050] S103. Determine the tolerance boundary of the single-wall corrugated pipe to be processed. The tolerance boundary is an interval that includes the upper limit angle threshold and the lower limit angle threshold.

[0051] Among them, the tolerance boundary refers to the normal fluctuation range of the pipe support angle value set by the server for the current pipe material. It is the core judgment basis for controlling the tension state of the pipe material and is used to indicate the allowable range of the support angle when the pipe tension is in a stable state.

[0052] When S102 determines that tolerance boundary simulation does not need to be enabled, the server directly calls the preset standard tolerance boundary corresponding to the current pipe material standard entity parameter range. The upper and lower angle thresholds of this boundary are fixed values ​​pre-calibrated based on the tension response characteristics of conventional pipe materials. When S102 determines that tolerance boundary simulation needs to be enabled, the server executes the following correction process:

[0053] First, the difference between the current pipe's tolerance feature value and the corresponding standard entity parameter interval endpoint value is calculated to obtain the feature offset. Examples include the difference between the actual pipe wall thickness and the lower limit of the standard wall thickness, and the difference between the actual hardness and the upper limit of the standard hardness. Then, the server calls a preset tolerance offset mapping table, which records the correspondence between different feature offsets and boundary correction coefficients. The server matches the corresponding target boundary correction coefficient based on the calculated feature offset. Finally, the server uses the target boundary correction coefficient to correct the preset standard tolerance boundary. For example, when the pipe wall thickness is thin and the elasticity is high, the tolerance boundary interval is appropriately expanded to reduce the sensitivity of angle determination and avoid misjudgments caused by minor elastic deformation of the pipe. When the pipe hardness is high and the elasticity is low, the tolerance boundary interval is appropriately narrowed to improve the accuracy of angle determination and ensure that tension fluctuations can be detected in a timely manner. The server stores the corrected tolerance boundary in the controller as the basis for subsequent angle comparisons.

[0054] S104. The angle value of the tube support is detected in real time by an angle potential sensor;

[0055] Among them, the angle potential sensor refers to the potential sensor installed on the hinge shaft of the pipe support to detect the deflection angle of the support. It can convert the mechanical deflection angle of the support into a continuously changing electrical signal for real-time feedback of the pipe tension status. The pipe support refers to the deflectable support on the frame used to support the single-wall corrugated pipe. During the transportation process, the pipe will cause the support to deflect slightly due to the change in tension. It is a direct sensing component of the tension status. The angle value refers to the deflection angle of the pipe support relative to the initial reference position. It is a quantitative indicator reflecting the tension status of the pipe. The larger the angle value, the greater the tension of the pipe. The smaller the angle value, the smaller the tension of the pipe.

[0056] This step, continuously executed by the controller during the grooving operation, is the core component for obtaining real-time tension status. The pipe-passing support is hinged to the frame. After the pipe passes through the support rollers, its own weight and the conveying tension keep the support at an initial reference angle. An angle potential sensor is coaxially mounted with the hinge axis of the pipe-passing support, enabling real-time acquisition of the support's deflection angle and converting the angle value into a corresponding voltage or current signal, which is then transmitted to the controller. The controller collects and processes the output signal from the angle potential sensor according to a preset sampling frequency, removing high-frequency noise and interference to obtain a stable and accurate real-time angle value. During the grooving operation, when the pipe conveying tension changes, the pipe-passing support will undergo a slight angular deflection. The angle potential sensor can capture this change in real time and transmit the corresponding angle value to the controller, providing real-time data support for subsequent status comparison and speed adjustment.

[0057] S105. Compare the angle value with the tolerance boundary to obtain the comparison result;

[0058] This step is automatically triggered by the server immediately after the angle potential sensor collects the angle value of the pipe support in real time. It is the core intermediate link connecting angle detection and speed adjustment. Its core purpose is to transform the angle change of the pipe support (indirectly reflecting the change of pipe tension) into a clear and quantifiable pipe condition judgment result. This provides a clear logical basis for subsequent precise adjustment of the grooving traction speed, solving the problem of inaccurate tension condition judgment and blind speed adjustment in traditional adjustment methods. When the server executes this step, it first starts the threshold retrieval program to accurately obtain the tolerance boundary of the single-wall corrugated pipe to be processed from its own cache. Simultaneously, it extracts the upper limit angle threshold and lower limit angle threshold contained in the tolerance boundary. These two thresholds are exclusive judgment benchmarks adapted to the current pipe properties (conventional or non-standard), ensuring the relevance and accuracy of the condition judgment and avoiding misjudgment caused by using uniform thresholds.

[0059] After extraction, the server synchronously compares the pipe support angle value transmitted in real time by the angle potential sensor with the extracted upper and lower angle thresholds. The comparison process employs bidirectional synchronous judgment logic, simultaneously determining the relationship between the angle value and the two thresholds to ensure the comprehensiveness and accuracy of the judgment results. The entire comparison process is completed in milliseconds, guaranteeing real-time status determination and adapting to production conditions with rapid fluctuations in pipe tension. The specific comparison judgment logic is as follows:

[0060] If the server detects that the current angle value is greater than the upper limit angle threshold, it means that the deflection angle of the pipe support has exceeded the normal allowable range. Combined with the linkage between the pipe support and the pipe, the pipe exerts a large pushing force on the pipe support at this time. Therefore, it can be determined that the current state of the single-wall corrugated pipe to be processed is a taut state. This state is mainly caused by the grooving traction speed lagging behind the speed of the pipe production line. The upstream pipe is continuously conveyed while the grooving device moves too slowly, resulting in the pipe being excessively stretched and the tension increasing.

[0061] If the server detects that the current angle value is less than the lower limit angle threshold, it means that the deflection angle of the pipe support is lower than the normal allowable range. At this time, the support force of the pipe on the pipe support is insufficient, and it can be determined that the current state of the single-wall corrugated pipe to be processed is a relaxed state. This state is mainly caused by the grooving traction speed being faster than the pipe production line speed. The grooving device excessively pulls the pipe, causing the pipe to become loose, sag, and reduce tension.

[0062] If the server detects that the current angle value is between the upper and lower angle thresholds, it means that the deflection angle of the pipe support is within the normal allowable range, the force of the pipe on the pipe support is stable, and the current state of the single-wall corrugated pipe to be processed can be determined to be normal. At this time, the pipe is transported smoothly, the tension is within a reasonable range, and the grooving traction speed is basically synchronized with the speed of the pipe production line, so there is no need to adjust the speed.

[0063] After completing the state determination, the server directly identifies the current state (one of three: tense, relaxed, or normal) as the comparison result, synchronously stores it in its own cache, and immediately transmits the comparison result to the controller. This provides a clear instruction basis for the controller to subsequently execute the grooving traction speed adjustment step. The entire comparison process is fully automated and real-time, requiring no manual intervention. This solves the problem of inaccurate quantification of tension state in traditional methods, while ensuring the speed and accuracy of state determination. It can quickly respond to subtle changes in pipe tension, laying a solid foundation for the subsequent accurate and rapid adjustment of grooving traction speed. This, in turn, ensures uniform grooving depth and stable wave pitch, improving the grooving processing quality of single-wall corrugated pipes.

[0064] S106. Adjust the grooving traction speed based on the comparison results.

[0065] Among them, the grooving traction speed refers to the moving speed of the grooving device along the pipe production direction, and its synchronization with the speed of the pipe production line directly affects the grooving quality.

[0066] The core purpose of this step is to precisely adjust the grooving traction speed based on the real-time tension of the pipe, achieving dynamic synchronization with the speed of the pipe production line. This solves the problems of traditional adjustment methods, such as coarse speed regulation, slow response, and inability to adapt to pipe tension fluctuations, fundamentally ensuring the uniformity of grooving depth and the stability of wave pitch. When the server executes this step, it first retrieves the comparison results and executes the corresponding differentiated speed adjustment logic based on different comparison results. The entire process is automated and requires no manual intervention.

[0067] If the comparison result indicates a taut state, it means the pipe is being excessively stretched, and the grooving traction speed is lagging behind the pipe production line speed. If the speed isn't reduced in time, it can lead to pipe stretching deformation, shallow grooving depth, or excessive wave pitch deviation. In this case, the server first initiates a deviation calculation program to calculate the difference between the current pipe support angle value and the upper limit angle threshold, obtaining the first instantaneous deviation. The magnitude of this first instantaneous deviation directly reflects the severity of the pipe's tautness; the larger the deviation, the greater the pipe tension and the more severe the tautness, requiring a greater speed reduction. After calculation, the server, based on the preset deviation-speed correlation rule and the specific value of the first instantaneous deviation, determines the corresponding reduction in traction speed to ensure a precise match between the speed reduction and the degree of tautness, avoiding insufficient speed reduction that fails to alleviate tautness or excessive speed reduction that causes sudden loosening of the pipe. Subsequently, the server converts the reduction in traction speed into a command to reduce the servo motor speed and sends it to the controller. The controller drives the servo motor to reduce its speed, which in turn drives the grooving device to move slowly downstream along the linear guide assembly, reducing the grooving traction speed and gradually reducing the tension of the pipe until the angle value of the pipe support falls back to within the tolerance boundary, and the pipe returns to normal.

[0068] If the comparison result indicates a relaxed state, it means that the current pipe is slack and sagging, and the grooving traction speed is faster than the pipe production line speed. If the speed is not increased in time, it will lead to pipe stacking, grooving position displacement, and uneven wave pitch. At this time, the server starts the deviation calculation program to calculate the difference between the lower limit angle threshold and the current pipe support angle value, obtaining the second instantaneous deviation. The larger the second instantaneous deviation, the more serious the pipe slack, and the greater the required speed increase. Then, according to the preset deviation-speed correlation rule, combined with the specific value of the second instantaneous deviation, the server determines the corresponding traction speed increase to ensure that the speed increase is accurately matched with the degree of slack, avoiding insufficient speed increase to alleviate slack, or excessive speed increase causing the pipe to suddenly tighten. Subsequently, the server converts the traction speed increase into a servo motor speed increase command and sends it to the controller. The controller drives the servo motor to increase its speed, driving the grooving device to move slowly upstream along the linear guide assembly, increasing the grooving traction speed, gradually increasing the pipe tension, until the pipe support angle value returns to within the tolerance boundary, and the pipe returns to normal.

[0069] If the comparison result is normal, it indicates that the current pipe tension is stable, and the grooving traction speed is basically synchronized with the pipe production line speed. No speed adjustment is needed. At this time, the server does not send any speed adjustment commands, maintaining the current speed of the servo motor to ensure the grooving device moves at a stable speed, continuously performing uniform grooving operations. The entire speed adjustment process forms a closed-loop control. The server dynamically adjusts in real time based on the comparison results, ensuring both the accuracy and timeliness of speed adjustment while avoiding problems such as speed overshoot and oscillation. This effectively solves the tension fluctuation problem caused by the easy deformation and unstable wave pitch of single-wall corrugated pipes, ensuring continuous and stable grooving operations and significantly improving grooving processing quality and production efficiency.

[0070] In some embodiments, after calculating the first or second instantaneous deviation, execution can be triggered synchronously to accurately determine the change in traction speed. The server pre-stores the proportional-integral-derivative (PID) algorithm. During calculation, the first or second instantaneous deviation is used as the algorithm input signal. The proportional element quickly responds to the deviation, the integral element eliminates steady-state error, and the derivative element predicts the trend of deviation change, performing comprehensive calculations on the deviation signal. During the calculation process, the server calls preset PID parameters (proportional coefficient, integral time, derivative time) to adapt to the working conditions of single-wall corrugated pipes, which are prone to sudden tension changes and elastic deformation, ensuring accurate calculation results. Finally, the algorithm outputs the corresponding decrease or increase in traction speed, which is transmitted to the controller, providing a quantitative basis for precise adjustment of the slotting traction speed, avoiding speed overshoot, oscillation, or under-adjustment, and ensuring speed regulation stability and accuracy.

[0071] In the above embodiment, a flexible synchronous control logic is constructed based on the actual physical properties of the pipe, using the change in the support angle as the tension sensing carrier, and adaptive threshold and PID speed regulation as the core. This effectively solves the technical problems of existing traditional grooving machines that rely on floating machine displacement detection, are easily deformed by the thin wall of single-wall corrugated pipes, have poor pitch stability, and are greatly disturbed by the fluctuation of pipe tension thrust, resulting in detection distortion, adjustment lag, and inaccurate response. This leads to uneven grooving depth, excessive pitch deviation, and easy scrapping of pipes. In this way, adaptive compatibility and adaptation of single-wall corrugated pipes with different batches and different physical properties are achieved, ensuring high-precision dynamic synchronization between the grooving traction speed and the pipe production line speed, stably controlling the uniformity of grooving depth and pitch accuracy, reducing scrap rate, and improving the grooving processing quality and the stability and production efficiency of continuous automated production.

[0072] The server in this application embodiment is described below from a hardware processing perspective. Please refer to [link / reference]. Figure 3 This is a schematic diagram of the physical device structure of a server in an embodiment of this application.

[0073] It should be noted that, Figure 3The server structure shown is merely an example and should not impose any limitations on the functionality and scope of use of the embodiments of this application.

[0074] like Figure 3 As shown, the server includes a Central Processing Unit (CPU) 301, which can perform various appropriate actions and processes based on a program stored in Read-Only Memory (ROM) 302 or a program loaded from storage portion 308 into Random Access Memory (RAM) 303, such as performing the methods described in the above embodiments. The RAM 303 also stores various programs and data required for system operation. The CPU 301, ROM 302, and RAM 303 are interconnected via a bus 304. An Input / Output (I / O) interface 305 is also connected to the bus 304.

[0075] The following components are connected to I / O interface 305: input section 306 including audio input devices, push-button switches, etc.; output section 307 including a liquid crystal display (LCD) and audio output devices, indicator lights, etc.; storage section 308 including a hard disk, etc.; and communication section 309 including a network interface card such as a LAN (Local Area Network) card, modem, etc. Communication section 309 performs communication processing via a network such as the Internet. Drive 310 is also connected to I / O interface 305 as needed. Removable media 311, such as a disk, optical disk, magneto-optical disk, semiconductor memory, etc., are installed on drive 310 as needed so that computer programs read from them can be installed into storage section 308 as needed.

[0076] Specifically, according to embodiments of this application, the processes described above with reference to the flowcharts can be implemented as computer software programs. For example, embodiments of this application include a computer program product comprising a computer program carried on a computer-readable medium, the computer program including a computer program for performing the methods shown in the flowcharts. In such embodiments, the computer program can be downloaded and installed from a network via communication section 309, and / or installed from removable medium 311. When the computer program is executed by central processing unit (CPU) 301, it performs the various functions defined in this application.

[0077] It should be noted that specific examples of computer-readable storage media may include, but are not limited to: electrical connections having one or more wires, portable computer disks, hard disks, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM), flash memory, optical fiber, portable compact disc read-only memory (CD-ROM), optical storage devices, magnetic storage devices, or any suitable combination of the foregoing. In this application, a computer-readable storage medium can be any tangible medium containing or storing a program that can be used by or in conjunction with an instruction execution system, apparatus, or device.

[0078] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of this application. Each block in a flowchart or block diagram may represent a module, segment, or portion of code, which contains one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions indicated in the blocks may occur in a different order than those shown in the drawings.

[0079] Specifically, the server in this embodiment includes a processor and a memory. The memory stores a computer program. When the computer program is executed by the processor, it implements the flexible adjustment method of the single-wall corrugated pipe grooving machine provided in the above embodiment.

[0080] In another aspect, this application also provides a computer-readable storage medium, which may be included in the server described in the above embodiments; or it may exist independently and not assembled into the server. The storage medium carries one or more computer programs that, when executed by a processor of the server, cause the server to implement the flexible adjustment method for the single-wall corrugated pipe grooving machine provided in the above embodiments.

[0081] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit it. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

[0082] As used in the above embodiments, depending on the context, the term "when..." can be interpreted as meaning "if...", "after...", "in response to determining...", or "in response to detecting...". Similarly, depending on the context, the phrase "when determining..." or "if (the stated condition or event) is interpreted as meaning "if determining...", "in response to determining...", "when (the stated condition or event) is detected", or "in response to detecting (the stated condition or event)".

[0083] Those skilled in the art will understand that all or part of the processes in the methods of the above embodiments can be implemented by a computer program instructing related hardware. This program can be stored in a computer-readable storage medium, and when executed, it can include the processes described in the above method embodiments. The aforementioned storage medium includes various media capable of storing program code, such as ROM or random access memory (RAM), magnetic disks, or optical disks.

Claims

1. A flexible adjustment method for a single-wall corrugated pipe grooving machine, characterized in that, The method includes: The basic physical parameters of the single-wall corrugated pipe to be processed are obtained by scanning the batch barcode. The basic entity parameters are compared with the preset standard entity parameter range to determine whether to enable tolerance boundary deduction. Determine the tolerance boundary of the single-walled corrugated pipe to be processed, wherein the tolerance boundary is an interval including an upper limit angle threshold and a lower limit angle threshold; The angle value of the tube support is detected in real time using an angle potential sensor; The angle value is compared with the tolerance boundary to obtain the comparison result; Adjust the grooving traction speed based on the comparison results.

2. The method according to claim 1, characterized in that, The step of comparing the basic entity parameters with a preset standard entity parameter range to determine whether to initiate tolerance boundary deduction specifically includes: Extract the tolerance feature values ​​from the basic entity parameters, wherein the tolerance feature values ​​include at least the pipe wall thickness and the material hardness; Determine whether the tolerance feature value is within the range of the standard entity parameters; If the tolerance boundary is within the standard entity parameter range, the tolerance boundary deduction will not be initiated, and the preset standard tolerance boundary corresponding to the standard entity parameter range will be determined as the tolerance boundary. If the parameter is not within the range of the standard entity parameters, then the tolerance boundary deduction is initiated to determine the tolerance boundary.

3. The method according to claim 2, characterized in that, The step of initiating the tolerance boundary deduction to determine the tolerance boundary if the parameter is not within the standard entity parameter range specifically includes: The difference between the tolerance feature value and the endpoint value of the standard entity parameter range is calculated to obtain the feature offset; Based on a preset tolerance offset mapping table, the target boundary correction coefficient corresponding to the feature offset is determined. The tolerance offset mapping table records the correspondence between different feature offsets and boundary correction coefficients. The preset standard tolerance boundary is corrected based on the target boundary correction coefficient to obtain the tolerance boundary.

4. The method according to claim 1, characterized in that, The step of comparing the angle value with the tolerance boundary to obtain the comparison result specifically includes: Obtain the upper and lower angle thresholds in the tolerance boundary; If the angle value is greater than the upper limit angle threshold, then the current state of the single-wall corrugated pipe to be processed is determined to be a taut state. If the angle value is less than the lower limit angle threshold, then the current state of the single-wall corrugated pipe to be processed is determined to be the relaxed state. If the angle value is between the upper limit angle threshold and the lower limit angle threshold, then the current state of the single-wall corrugated pipe to be processed is determined to be a normal state. The current state is determined as the comparison result.

5. The method according to claim 4, characterized in that, The step of adjusting the grooving traction speed based on the comparison results specifically includes: If the comparison result is a tense state, then the difference between the angle value and the upper limit angle threshold is calculated to obtain the first instantaneous deviation; The amount of speed reduction is determined based on the first instantaneous deviation, so as to reduce the grooving speed; If the comparison result is in a relaxed state, then the difference between the lower limit angle threshold and the angle value is calculated to obtain the second instantaneous deviation; The increase in traction speed is determined based on the second instantaneous deviation in order to improve the grooving traction speed; If the comparison result is normal, then the current grooving traction speed remains unchanged.

6. The method according to claim 5, characterized in that, It also includes a method for calculating the change in traction speed, the calculation method comprising: The proportional-integral-differential algorithm is used to calculate the first instantaneous deviation or the second instantaneous deviation to obtain the decrease in traction speed or the increase in traction speed.

7. A single-wall corrugated pipe grooving machine, used to implement the flexible adjustment method of the single-wall corrugated pipe grooving machine as described in claim 1, wherein the single-wall corrugated pipe grooving machine includes a frame, a plastic corrugated pipe grooving device, a position sensor, and a controller, the grooving device includes a servo motor and a spiral cutter head assembly, and the controller is electrically connected to the position sensor and the servo motor, characterized in that: The frame is also equipped with an angle potential sensor and a pipe support, the pipe support being used to support the plastic corrugated pipe. The angle potential sensor is connected to the tube support and is used to detect the angle change of the tube support; The controller is electrically connected to the angle potential sensor and is used to adjust the grooving traction speed according to the signal from the angle potential sensor.

8. A server, characterized in that, The server includes: one or more processors and a memory; the memory is coupled to the one or more processors, the memory being used to store computer program code, the computer program code including computer instructions, and the one or more processors invoking the computer instructions to cause the server to perform the method as described in any one of claims 1-6.

9. A computer-readable storage medium comprising instructions, characterized in that, When the instruction is executed on the server, it causes the server to perform the method as described in any one of claims 1-6.

10. A computer program product, comprising a computer program, characterized in that, When the computer program is run on the server, it causes the server to perform the method as described in any one of claims 1-6.

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