Automated spherical plate pressing method

Abstract

The present disclosure generally relates to a method and apparatus for forming a plate. The method for forming a plate includes providing a plate to a press of an assembly system. The plate is formed in the press. The plate is transported to an inspection station of the assembly system and inspected. The plate is transported to a trimming station of the assembly system. The plate is cut using a trimming head of the trimming station and inspected at the trimming station. A controller has stored therein instructions that, when executed by a processor, cause the system to form the plate.

Description

[Technical Field]

[0001] SUMMARY OF THE INVENTION Embodiments of the present disclosure generally relate to methods for forming segmented spherical plates (e.g., those used to form spherical storage tanks). [Background technology]

[0002] Conventional spherical plate molding methods are cumbersome, time-consuming, and require excessive man-hours to complete.

[0003] Thus, there is a need for an improved method for forming segmented plates.

[0004] overview The present disclosure generally relates to methods for forming segmented spherical plates (e.g., those used to form spherical storage tanks).

[0005] In one embodiment, an assembly system is disclosed. The assembly system includes a press, a first manipulator, a second manipulator, one or more manipulator guide rails, an inspection station, and a trimming station. The press includes a base portion, an upper portion, one or more vertical supports, a ram, and an operating crucible. The first manipulator and the second manipulator support a plate within the press. The one or more manipulator guide rails are coupled to the manipulator guide rails. The inspection station includes an inspection platform and one or more inspection platform guide rails. The trimming station includes one or more trimming arm supports, a trimming stage, and a trimming arm supported by one or more trimming arm supports. The trimming arm includes a trimming head.

[0006] In another embodiment, a controller for an assembly system is disclosed. The controller has stored thereon instructions that, when executed by a processor, cause the system to form a plate in a press by moving the plate between a ram and a working crucible and stroking the ram toward the working crucible. The controller transports the plate to an inspection station where it is inspected. The controller cuts the plate at a trimming station. The controller receives sensor readings from sensors in the assembly system and continuously monitors the forming, inspection, and trimming of the plate.

[0007] In yet another embodiment, a method is disclosed. The method includes providing a plate to a press of an assembly system. The plate is formed in the press. The plate is transported to an inspection station of the assembly system and inspected. The plate is transported to a trimming station of the assembly system. The plate is cut using a trimming head of the trimming station and inspected at the trimming station.

[0008] It is contemplated that elements and features of one embodiment may be beneficially incorporated in other embodiments without further recitation.

[0009]

[0009] So that the above-mentioned features of the present disclosure can be understood in detail, a more particular description of the disclosure briefly summarized above can be had by reference to embodiments, some of which are illustrated in the accompanying drawings. It should be noted, however, that the accompanying drawings illustrate only exemplary embodiments and should not be considered limiting in scope, since the present disclosure may admit of other equally effective embodiments. [Brief explanation of the drawings]

[0010] [Figure 1] 1 illustrates an assembly system according to an embodiment of the present disclosure. [Figure 2A] 1 illustrates a perspective view of a press according to an embodiment of the present disclosure. [Figure 2B] 1 illustrates a front view of a press according to an embodiment of the present disclosure. [Figure 2C] 1 illustrates a side view of a press according to an embodiment of the present disclosure. [Figure 3A] 1 illustrates a front view of an inspection platform of an inspection station according to an embodiment of the present disclosure. [Figure 3B] 1 illustrates a top view of an inspection platform of an inspection station according to an embodiment of the present disclosure. [Figure 3C] 1 illustrates a side view of an inspection platform of an inspection station according to an embodiment of the present disclosure. [Figure 4] 1 illustrates a trimming station according to an embodiment of the present disclosure. [Figure 5] 2 shows a control schematic for use in the assembly system of FIG. 1 according to an embodiment of the present disclosure. [Figure 6] 1 illustrates a method for processing a plate according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0011]

[0020] The present disclosure generally relates to an apparatus and method for forming segmented plates (e.g., those used to form spherical storage tanks). The apparatus includes an assembly system including a press, a first manipulator, a second manipulator, one or more manipulator guide rails, an inspection station, and a trimming station. The press includes a base, an upper portion, one or more vertical supports, a ram, and an operating crucible. The first manipulator and the second manipulator support the plate within the press. The one or more manipulator guide rails are coupled to the manipulator guide rails. The inspection station includes an inspection platform and one or more inspection platform guide rails. The trimming station includes one or more trimming arm supports, a trimming stage, and a trimming arm supported by one or more trimming arm supports. The trimming arm includes a trimming head. A method for forming a plate includes providing a plate to the press of the assembly system. The plate is formed in the press. The plate is transported to an inspection station of the assembly system and inspected. The plate is transported to a trimming station of the assembly system. The plate is cut using a trimming head of the trimming station and inspected at the trimming station. The controller has stored therein instructions that, when executed by the processor, cause the system to shape the plate.

[0012] FIG. 1 illustrates an assembly system 100. In some embodiments, the assembly system 100 is configured to form a plate 102 into a spherical shape as a component into a storage tank or container. The assembly system 100 includes a press 104, an inspection station 106, and a trimming station 108. The plate 102 is supported within the press 104 by a first manipulator 110 and a second manipulator 112. The first manipulator 110 and the second manipulator 112 are mounted on manipulator guide rails 114. The first manipulator 110 (e.g., a gripper, holding member, etc.) and the second manipulator 112 (e.g., a gripper, holding member, etc.) are configured to move laterally and longitudinally within the press 104 via the manipulator guide rails 114. The first manipulator 110 and the second manipulator 112 move within the press 104, thereby moving the plate 102 within the press 104 and forming the plate 102.

[0013] 2A to 2C show the press 104. FIG. 2A shows a perspective view of the press 104. FIG. 2B shows a front view of the press 104. FIG. 2C shows a side view of the press 104. The press 104 includes a vertical support 220, a base 222, a top 224, a ram 225, a base plate 226, and an operating crucible 227. The vertical support 220 spans between the base 222 and the top 224. The operating crucible 227 is attached to the base plate 226. The base plate 226 is disposed on the base 222 of the press 104. The press 104 has a height H1 of approximately 8000 mm to approximately 9000 mm. The press 104 has a length L1 of approximately 6000 mm to approximately 7000 mm. A second height H2 from the upper surface of the base portion 222 to the bottom surface of the top portion 224 is approximately 3500 mm to approximately 4500 mm. A second length L2 from the inner surface of one vertical support 220 to the inner surface of the other vertical support 220 is approximately 4000 mm to approximately 5000 mm. The press 104 has a width W1 of approximately 2000 mm to approximately 3000 mm. The base plate 226 has a third length L3 of approximately 3000 mm to approximately 4000 mm and a second width W2 of approximately 2500 mm to approximately 3500 mm.

[0014] As the first manipulator 110 and the second manipulator 112 move the plate 102 within the press 104, a ram 225 manipulates the plate 102 within a working crucible 227. In some examples, the first manipulator 110 and the second manipulator 112 each have a groove therein for receiving and holding the plate 102. The ram 225 is configured to stroke downward toward the working crucible 227 to form the plate 102. The ram 225 then strokes upward to release the plate 102, allowing the first manipulator 110 and the second manipulator 112 to move the plate 102 within the press 104 and continue to form the plate 102 using another downward stroke of the ram 225. The press 104 is configured to repeat this process until the plate 102 is formed.

[0015] 3A-3C show the inspection platform 130 of the inspection station 106. FIG. 3A shows a front view of the inspection platform 130 of the inspection station 106. FIG. 3B shows a top view of the inspection platform 130 of the inspection station 106. FIG. 3C shows a side view of the inspection platform 130 of the inspection station 106. The inspection station 106 includes the inspection platform 130 and an inspection platform guide rail 132. The inspection platform 130 includes a base plate 332, a support gusset 334, an adjustment rail 336, a support 338, and a plurality of wheels 340. The support 338 of the inspection platform 130 can be adjusted using the adjustment rail 336. The base plate 332 can be moved along the adjustment rail 336 to adjust the inspection platform 130 to predetermined specifications and tolerances. The adjustment rail 336 is coupled to the support gusset 334. The support gusset 334 is coupled to the support 338 and is configured to support the support 338 when the support 338 supports the plate 102 .

[0016] The plate 102 is transported from the press 104 along the manipulator guide rails 114 to the inspection station 106. The plate 102 is placed on the inspection platform 130, and more specifically, the plate 102 is placed on supports 338. In some embodiments, the manipulator guide rails are positioned to allow the first manipulator 110 to pass over the inspection platform 130, facilitating placement of the plate 102 on the inspection platform 130. The inspection platform 130 is configured to determine whether the plate 102 has been formed within predetermined specifications and tolerances. In some embodiments, the predetermined specifications and tolerances of the plate 102 are determined by ensuring that the plate 102 is in contact with each of the supports 338. As shown in FIGS. 3A-3C , the inspection platform 130 includes nine supports 338, although more or fewer supports 338 are contemplated by the present disclosure. To achieve a desired specification for the radius of the plate 102, for example, the plate 102 should contact each of the nine supports 338. If the plate 102 is not within the predetermined specifications and tolerances, the plate 102 is returned to the press 104 to further shape the plate 102. If the plate 102 is within the predetermined specifications and tolerances, the inspection platform 130 is transported along the inspection platform guide rails 132 to the trimming station 108.

[0017] 4 illustrates the trimming station 108. The trimming station 108 includes a trimming arm 152, one or more trimming arm supports 154, and a trimming stage 156. The trimming arm 152 includes a trimming head 460. The trimming arm 152 may be configured to be controlled by a computer numerically controlled (CNC) device. The trimming head 460 is configured to cut the plate 102 in the X-axis, Y-axis, and Z-axis to trim and bevel the edge of the plate 102. The trimming head 460 may be a high-definition plasma cutting torch, an oxy-fuel cutting torch, or other suitable cutting torch, depending on the material and thickness of the plate.

[0018] The trimming station 108 is configured to measure the accuracy of the cuts made on the plate 102. If the cuts made on the plate 102 are not within predetermined specifications and tolerances, the plate 102 is further cut using the trimming head 460. If the plate 102 is within predetermined specifications and tolerances, the plate 102 is removed from the assembly system 100.

[0019] FIG. 5 shows a control schematic 500 for use with the assembly system 100 of FIG. 1. The controller 160 is configured to receive data or input as sensor readings 502 from each of the press 104, the inspection station 106, and the trimming station 108. The controller 160 includes or is in communication with a system model 506 of the assembly system 100. The system model 506 includes a specification and tolerance model. The system model 506 is a program configured to estimate the number of strokes and pressure of the ram 225, the distance and direction of travel of the plate 102 within the press 104, the specifications and tolerances of the plate 102 at the inspection station 106, and the cuts made at the trimming station 108. The controller 120 is further configured to record the readings and calculations 504.

[0020] The readings and calculations 504 include the previous sensor readings 502 as well as any other previous sensor readings within the assembly system 100. The readings and calculations 504 also include calculations stored after the sensor readings 502 have been measured by the controller 160 and run through a system model 506. Thus, the controller 160 is configured to obtain both the recorded readings and calculations 504 as well as store the readings and calculations 504 for future use. By maintaining previous readings and calculations, the controller 160 can adjust the system model 506 over time to improve the efficiency and accuracy of the assembly system 100. The controller 160 is further configured to adjust the assembly process to meet specifications and tolerance models by continuously monitoring the processing of the plates 102.

[0021]

[0030] In the embodiments described herein, the controller 160 includes a programmable central processing unit (CPU) operating with memory and mass storage, an input control unit, and a display unit (not shown). The controller 160 oversees the forming, inspection, and trimming of the plate 102. Support circuitry is coupled to the CPU for supporting the processor in a conventional manner. In some embodiments, the controller 160 includes multiple controllers 160, and the recorded readings and calculations 504 and the system model 506 are stored in a controller separate from the controller 160 that runs the assembly system 100. In other embodiments, all of the system model 506 and the stored readings and calculations 504 are stored in the controller 160.

[0022] 6 illustrates a method 600 for processing a plate 102. In operation 601, the plate 102 is provided to the press 104 of the assembly system 100. The plate 102 is supported in the press 104 by a first manipulator 110 and a second manipulator 112. The press 104 includes a ram 225 and an operating crucible 227.

[0023] In operation 602, the press 104 forms the plate 102. The ram 225 of the press 104 is stroked downward toward the working crucible 227 with the plate 102 positioned between the ram 225 and the working crucible 227. The ram 225 is stroked upward away from the working crucible to allow the first manipulator 110 and the second manipulator 112 to move the plate 102 within the press 104 for additional forming. The plate 102 is repeatedly pressed between the ram 225 and the working crucible 227 until the plate 102 is formed.

[0024] In operation 603, the plate 102 is transported to the inspection station 106. The plate 102 is placed on the inspection platform 130. The inspection platform 130 includes a plurality of supports 338.

[0025] In operation 604, the plate 102 is inspected. The inspection platform 130 is configured to determine whether the plate 102 is formed within predetermined specifications and tolerances. The predetermined specifications and tolerances of the plate 102 are determined, in some embodiments, by ensuring that the plate 102 is in contact with each of the supports 338. If the plate 102 is not within the predetermined specifications and tolerances, the plate 102 is returned to the press 104 and operation 602 is repeated. If the plate 102 is within the predetermined specifications and tolerances, the method 600 proceeds to operation 605.

[0026] In operation 605, the inspection platform 130 is transported to the trimming station 108. In operation 606, the plate 102 is cut by the trimming head 460 of the trimming arm 152. The trimming head 460 is configured to cut the plate 102 in the X-axis, Y-axis, and Z-axis and to trim and bevel the edges of the plate 102. The trimming head 460 may be a high-definition plasma cutting torch, an oxy-fuel cutting torch, or other suitable cutting torch, depending on the material and thickness of the plate.

[0027] In operation 607, the plate 102 is inspected at the trimming station 108. The trimming station 108 is configured to measure the accuracy of the cuts made on the plate 102. If the cuts made on the plate 102 are not within predetermined specifications and tolerances, the plate 102 is further cut using the trimming head 460 according to operation 606. If the plate 102 is within predetermined specifications and tolerances, the plate 102 is removed from the assembly system 100 for further processing.

[0028] In summary, a method and apparatus for forming a plate is provided. The method for forming a plate includes providing a plate to a press of an assembly system. The plate is formed in the press. The plate is transported to an inspection station of the assembly system and inspected. The plate is transported to a trimming station of the assembly system. The plate is cut using a trimming head of the trimming station and inspected at the trimming station. A controller has stored therein instructions that, when executed by a processor, cause the system to form the plate.

[0029] While the forgoing is directed to embodiments of the present disclosure, other and further embodiments of the present disclosure may be devised without departing from the basic scope thereof, which scope is determined by the following claims.

Claims

1. 1. A method for processing a plate, comprising: providing a plate to a press of an assembly system; forming a plate using the press; transporting the plate to an inspection station of the assembly system; inspecting the plate; transporting the plate to a trimming station of the assembly system; cutting the plate using a trimming head of the trimming station; and Inspecting the plate at the trimming station. A method comprising:

2. The method of claim 1 , further comprising determining whether the plate is formed within predetermined specifications and tolerances when inspecting the plate at the inspection station.

3. The method of claim 2 further comprising returning the plate to the press if the plate is not formed within predetermined specifications and tolerances.

4. The method of claim 3 further comprising additionally forming the plate if the plate is not formed within predetermined specifications and tolerances.

5. The method of claim 1 , wherein the trimming head comprises a plasma cutting torch or a gas cutting torch.

6. The method of claim 1 , further comprising: determining whether the plate is cut within predetermined specifications and tolerances when inspecting the plate at the trimming station.

7. The method of claim 6, further comprising additionally cutting the plate if the plate is not cut within predetermined specifications and tolerances.

8. 1. An assembly system, comprising: A press machine, Base part, Top, one or more vertical supports; Ram, and a press having an operating crucible; a first manipulator; a second manipulator; and one or more manipulator guide rails to which the first manipulator and the second manipulator are coupled; 1. An inspection station comprising: Inspection platform, and an inspection station comprising one or more inspection platform guide rails; A trimming station, comprising: one or more trimming arm supports; Trimming stage, and a trimming station including a trimming arm supported by the one or more trimming arm supports and having a trimming head; Including, The assembly system wherein the first manipulator and the second manipulator support a plate within the press.

9. The assembly system of claim 8 , wherein the trimming head comprises a high-definition plasma cutting torch or a gas cutting torch.

10. The assembly system of claim 8 , further comprising a working crucible disposed on a base plate, said base plate being disposed on said base portion of said press.

11. the inspection platform: one or more base plates; one or more support gussets coupled to the base plate; one or more adjustment rails; one or more supports coupled to the one or more support gussets; and Multiple wheels The assembly system of claim 8 further comprising:

12. The assembly system of claim 11 , wherein the support is configured to support the plate.

13. The assembly system of claim 8 , further comprising a controller configured to receive sensor readings from the assembly system.

14. The assembly system of claim 13 , wherein the controller compares the sensor readings from the assembly system with a system model including specifications and tolerance models to determine adjustments to the assembly system.

15. A controller of an assembly system having instructions recorded thereon, the instructions, when executed by a processor, causing the system to: forming the plate in a press by moving the plate between a ram and a working crucible and stroking the ram toward the working crucible; transporting the plate to an inspection station; inspecting the plate at the inspection station; and cutting the plate at a trimming station wherein the controller receives sensor readings from sensors in the assembly system and continuously monitors the forming, inspection, and trimming of the plate.

16. The controller of claim 15 , further causing the assembly system to compare forming, inspecting and cutting the plate to a system model including a specification and tolerance model.

17. The controller of claim 15 further adjusts forming and cutting in response to sensor readings of the assembly system.

18. 16. The controller of claim 15, further comprising: recording the sensor readings in a memory.

19. 16. The controller of claim 15, further causing cutting in the X, Y and Z axes, and trimming and beveling edges of the plate.

20. 16. The controller of claim 15, further causing the plate to be repeatedly pressed between the ram and the operating crucible.

Images