Battery pack powered roll groover

Abstract

A roll groover including a housing, an inner roller configured to be received in an inner circumference of a workpiece provided on the housing, and a groove roll configured to produce a groove on the workpiece provided on the housing. The roll groover includes a first motor to move the groove roll towards and away from the workpiece and a second motor to move the groove roll around a track and a circumference of the workpiece. The roll groover includes an electronic processor connected to the first motor and the second motor. The electronic processor is configured to operate the first motor to adjust the groove depth on the workpiece and the second motor to produce the groove on the workpiece.

Description

BATTERY PACK POWERED ROLL GROOVERBACKGROUND

[0001] In the pipe fitting industry, different methods are used to join two separate pieces of piping together. In one example, ends of the pipes are threaded and a threaded adapter is used to join the pipes together. An alternative to a threaded connection is a grooved connection.Specifically, a pipe is cut to the desired length and a groove is rolled onto an end of the pipe. A grooved adapter is then used to join the pipe to another pipe.SUMMARY

[0002] Grooved pipe connections are especially useful to join pipes carrying water and / or steam and to provide a water-tight seal between the pipes. A roll groover is used to produce a groove on the pipes. Roll groovers are typically mechanical devices that are placed on a pipe. A skilled user uses a crank mechanism to rotate the roll groover around the pipe to roll the groove onto the pipe. The crank mechanism involved manually rotating a crank by hand to rotate the roll groover.

[0003] Current roll groovers require skilled users to operate and take a large amount of time to complete one operation. Accordingly, there is a need for automated roll groovers that are simple to operate and reduce the operation time compared to current roll groovers.

[0004] Some embodiments provide a roll groover including a housing, an inner roller configured to be received in an inner circumference of a workpiece provided on the housing, and a groove roll configured to produce a groove on the workpiece provided on the housing. The roll groover includes a first motor to move the groove roll towards and away from the workpiece and a second motor to move the groove roll around a track and a circumference of the workpiece. The roll groover includes an electronic processor connected to the first motor and the second motor. The electronic processor is configured to operate the first motor to adjust the groove depth on the workpiece and the second motor to produce the groove on the workpiece.

[0005] Further embodiments provide a method for detecting that a pipe is inserted a first distance on a roll groover. The method includes receiving, with a controller of the roll groover, an input from a sensor coupled to the roll groover, determining, with the controller of the roll groover, based on the input, that the pipe is inserted the first distance on the roll groover, andinitiating, with the controller of the roll groover, a grooving process in response to the pipe being inserted the first distance on the roll groover.

[0006] Even further embodiments provide a system for measuring a groove depth on a pipe. The system includes a pipe and a roll groover. The roll groover includes a housing, an eccentric grooving shaft, one or more sensors, a groove roll provided on the housing and configured to produce a groove on the pipe, one or more motors provided within the housing and configured to drive the groove roll, and a controller electrically connected to the one or more motors and the sensor. The controller is configured to operate the one or more motors to perform a first operation of adjusting a groove depth on the pipe, operate the one or more motors to perform a second operation of producing the groove on the pipe, receive an input from the sensor, and determine a groove depth of the groove on the pipe based on the input from the sensor.

[0007] Even further embodiments provide a roll groover. The roll groover includes a housing, an inner roller provided on the housing and configured to be received in an inner circumference of a pipe, a groove roll provided on the housing and configured to produce a groove on the pipe, a motor provided within the housing and configured to drive the groove roll, and an electronic processor electrically connected to the motor. The electronic processor is configured to determine a pipe thickness of the pipe, determine a clamp force based on the pipe thickness, compare the clamp force to a power measurement of the motor, and determine that the pipe is properly clamped to the roll groover in response to the power measurement being within a tolerance range of a threshold value proportional to the pipe thickness.

[0008] Before any embodiments are explained in detail, it is to be understood that the embodiments are not limited in its application to the details of the configuration and arrangement of components set forth in the following description or illustrated in the accompanying drawings. The embodiments are capable of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof are meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereofare used broadly and encompass both direct and indirect mountings, connections, supports, and couplings.

[0009] In addition, it should be understood that embodiments may include hardware, software, and electronic components or modules that, for purposes of discussion, may be illustrated and described as if the majority of the components were implemented solely in hardware. However, one of ordinary skill in the art, and based on a reading of this detailed description, would recognize that, in at least one embodiment, the electronic-based aspects may be implemented in software (e.g., stored on non-transitory computer-readable medium) executable by one or more processing units, such as a microprocessor and / or application specific integrated circuits (“ASICs”). As such, it should be noted that a plurality of hardware and software based devices, as well as a plurality of different structural components, may be utilized to implement the embodiments. For example, “servers,” “computing devices,” “controllers,” “processors,” etc., described in the specification can include one or more processing units, one or more computer-readable medium modules, one or more input / output interfaces, and various connections (e.g., a system bus) connecting the components.

[0010] Relative terminology, such as, for example, “about,” “approximately,” “substantially,” etc., used in connection with a quantity or condition would be understood by those of ordinary skill to be inclusive of the stated value and has the meaning dictated by the context (e.g., the term includes at least the degree of error associated with the measurement accuracy, tolerances [e.g., manufacturing, assembly, use, etc.] associated with the particular value, etc.). Such terminology should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression “from about 2 to about 4” also discloses the range “from 2 to 4”. The relative terminology may refer to plus or minus a percentage (e.g., 1%, 5%, 10%, or more) of an indicated value.

[0011] It should be understood that although certain drawings illustrate hardware and software located within particular devices, these depictions are for illustrative purposes only. Functionality described herein as being performed by one component may be performed by multiple components in a distributed manner. Likewise, functionality performed by multiple components may be consolidated and performed by a single component. In some embodiments, the illustrated components may be combined or divided into separate software, firmware and / orhardware. For example, instead of being located within and performed by a single electronic processor, logic and processing may be distributed among multiple electronic processors. Regardless of how they are combined or divided, hardware and software components may be located on the same computing device or may be distributed among different computing devices connected by one or more networks or other suitable communication links. Similarly, a component described as performing particular functionality may also perform additional functionality not described herein. For example, a device or structure that is “configured” in a certain way is configured in at least that way but may also be configured in ways that are not explicitly listed.

[0012] Other aspects of the embodiments will become apparent by consideration of the detailed description and accompanying drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0013] FIG. 1A is a first perspective view of a roll groover in accordance with some embodiments.

[0014] FIG. IB is a second perspective view of a roll groover in accordance with some embodiments.

[0015] FIG. 2 is a first perspective view of the roll groover of FIG. 1A engaged with a workpiece in accordance with some embodiments.

[0016] FIG. 3 is a plan view of a workpiece interface of the roll groover of FIG. 1A in accordance with some embodiments.

[0017] FIG. 4 is a front view of the roll groover of FIG. 1A in accordance with some embodiments.

[0018] FIG. 5 is a perspective view of an eccentric grooving shaft in accordance with some embodiments.

[0019] FIG. 6 is a user interface of the roll groover of FIG. 1 A in accordance with some embodiments.

[0020] FIG. 7 is a block diagram of the roll groover of FIG. 1 A in accordance with some embodiments.

[0021] FIG. 8A is a block diagram of sensors of the roll groover of FIG. 1 A in accordance with some embodiments.

[0022] FIG. 8B is a block diagram of an inertial measurement of the roll groover of FIG. 1A in accordance with some embodiments.

[0023] FIGS. 9A and 9B are a flowchart of an example method 900 for performing a grooving process on pipes of different thicknesses FIG. 10 is a flowchart of a method for detecting an improper setting of the roll groover of FIG. 1 A in accordance with some embodiments.

[0024] FIG. 11 is a flowchart of a method for shutting off the roll groover of FIG. 1 A when the roll groover is not rotating during a grooving process in accordance with some embodiments.

[0025] FIG. 12 is a flowchart of a method for shutting off the roll groover of FIG. 1A when an input setting is changed during a grooving process in accordance with some embodiments.

[0026] FIG. 13 is a flowchart of a method for illuminating the user interface the roll groover of FIG. 1A in accordance with some embodiments.

[0027] FIG. 14 is a flowchart of a method for detecting an insertion distance of a workpiece on the roll groover of FIG. 1A in accordance with some embodiments.

[0028] FIG. 15 is a flowchart of a shutting off the roll groover of FIG. 1A in response to a safety actuator being actuated of in accordance with some embodiments.

[0029] FIG. 16 is a flowchart of a method for outputting indications to an indicator of the roll groover of FIG. 1A in accordance with some embodiments.

[0030] FIG. 17 is a flowchart of a method for returning the roll groover of FIG. 1A to a starting position in accordance with some embodiments.DETAILED DESCRIPTION

[0031] FIGS. 1 A and IB illustrate an example embodiment of a roll groover 100. The roll groover 100 is configured to operate on a workpiece, for example, a metal pipe 200 (FIG. 3), or the like. The roll groover 100 includes a housing 105 and a handle 110 that forms part of the housing. The housing 105 includes a first end 115 having a workpiece interface 118 and a second end 120, opposite the first end 115. A battery pack interface 125 that receives a batterypack 126 is provided in the housing 105 between the handle 110 and the second end 120. The battery pack 126 is, for example, a power tool battery pack having a nominal voltage of 12 V, 18 V, 36 V, 60 V, 80 V, or the like. In some embodiments, the roll groover 100 may be powered by an AC power source and may include a power cord that can be plugged into a wall outlet.

[0032] A user interface 130 is provided on a side surface 135 of the roll groover 100. The side surface 135 is between the first end 115 and the second end 120 of the housing. A first safety actuator 140 is provided on the side surface 135. In the example illustrated, the first safety actuator 140 is provided on the side surface 135 close to the first end 115. The first safety actuator 140 may include a hinged portion that protrudes from the housing 105 such that when a user applies pressure to the first safety actuator 140 the hinged portion is moved a first distance. For example, a switch, such as stop switch 744 (FIG. 7), may be provided below the hinged portion of the first safety actuator 140 and pressure applied to the hinged portion may actuate the stop switch 744.

[0033] A work light 145 may be provided on the housing 105. For example, the work light 145 may be provide on the housing 105 at a first end 115 of the roll groover to illuminate a workpiece coupled to the workpiece interface 118. The work light 145 may be a light emitting diode (LED), a condensed fluorescent light (CFL), or any other suitable light source.

[0034] A second safety actuator 150 is provided on the housing 105 at the second end 120. The second safety actuator 150 may be an electric actuator or a physical actuator. For example, the second safety actuator 150 may be a physical button that actuates the stop switch 744 when a user applies pressure to the second safety actuator. The second safety actuator 150 may be flanked by two bumpers 155A, 155B to mitigate any accidental actuation of the second safety actuator 150. For example, the first bumper 155A may be provided above the second safety actuator 150 and the second bumper 155B may be provided below the second safety actuator 150.

[0035] FIG. 2 is a first perspective view of the roll groover 100 engaged with a workpiece, for example, the metal pipe 200. The pipe 200 is coupled to the roll groover 100 at the workpiece interface. The pipe 200 may be clamped to an exterior support (not show) or it may be free standing such that it is only supported by the roll groover. For example, when the pipe 200 is clamped to an exterior support, the roll groover 100 may be freestanding over a surfaceand may rotate about an axis of the pipe 200 to groove the pipe 200. As another example, when the pipe 200 is free standing, the roll groover 100 may be provided on a first surface and the pipe 200 may rotate about an axis to groove the pipe 200. When the roll groover 100 is provided on a surface it may be considered a “benchtop mode.”

[0036] FIG. 3 is a plan view of the workpiece interface 118 of the roll groover 100. The workpiece interface 118 includes an inner roller 300 that protrudes from the housing 105. The inner roller 300 is received on the inside of a pipe 200. The inner roller 300 is dimensioned to fit within the inner circumference of any pipe currently used in the industry for transporting water and steam. A groove roll 305 is provided on a circumferentially outer side of the inner roller 300. The groove roll 305 engages an outer circumference of the pipe 200 to roll a groove onto the pipe 200. A roll casing 310 is provided over the groove roll 305 such that the groove roll 305 is mounted and moves with the roll casing 310. The roll casing 310 with the groove roll 305 moves around a track 315. The groove roll 305 produces a groove on the pipe 200 by moving around the track 315.

[0037] FIG. 4 is a front view of the roll groover 100 including the workpiece interface 118. In some embodiments, the housing 105 of the roll groover 100 may be an outer housing provided over components of the roll groover 100. For example, the housing 105 may be made of plastic, metal, or a combination thereof and the components beneath the housing 105 may be made of metal. An inner housing 400 may be provided below the outer housing of the housing 105. The inner housing 400 may include a flat top region 402. For example, the flat top region 402 may be at a top side of the roll casing 310. The flat top region 402 ensures the roll groover 100 is properly calibrated by giving an exact on-tool angle (e.g., when a pipe 200 is received at the workpiece interface 118) of the roll groover 100 so the roll groover 100 may properly map its radial location with respect to the pipe 200. Another calibration feature may be provided by an etched line 405 on the groove roll 305. The etched line 405 also allows the roll groover 100 to properly map its radial location with respect to the pipe 200. For example, the groove roll 305 may be clocked so that when the roll groover is in a home (i.e., “top”) position, the etched line 405 is in a vertical position. However, in other embodiments, the etched line may be in an alternative position, such as horizontal in the home position, as required for a given application.FIG. 5 is a perspective view of an eccentric grooving shaft 500. The eccentric grooving shaft 500 may be the inner roller 300. For example, the eccentric grooving shaft 500 may be under an outer housing of the inner roller 300 and may include the groove roll 305. The eccentric grooving shaft includes a first shaft 505, a second shaft 510, and a third shaft 515. A printed circuit board (PCB) 520 is mounted circumferentially about the third shaft 515. For example, the PCB 520 is ring shaped with an inner circumference that is the same as an outer circumference of the third shaft 515 and an outer circumference that is at least twice the inner circumference. In some embodiments, the PCB 520 is stationary with respect to the eccentric grooving shaft 500. For example, a copper target (e.g., a copper protrusion) may be attached to one of the first shaft 505, the second shaft 510, and the third shaft 515 and the PCB 520 may include an inductive sensor that senses a presence of the copper target as the eccentric grooving shaft 500 rotates.

[0038] FIG. 6 illustrates a user interface 130 of the roll groover 100, according to some embodiments. The user interface 130 includes a power actuator 600, a depth tuning knob 605, a speed selection knob 610, clamp status indicators 615, and bumpers 620A, 620B. The power actuator 600 may be a button that a user may depress to turn the roll groover 100 on. For example, actuation of the power actuator 600 may send a signal to a controller of the roll groover, for example, controller 700 (FIG. 7), to begin drawing power from the battery pack 126 to be provided to at least one motor, for example motors 790, 795, for a grooving process. The depth tuning knob 605 may be a knob with a selection indication that a user may radially move to select a groove depth of the groove roll 305. For example, numbers (e g., 0 - 10) may be evenly spaced around an outside circumference of the depth tuning knob 605 on the housing 105 and a user may adjust the depth tuning knob 605 to align the selection indication with the number represents a groove depth the user desires. In one embodiment, the depth tuning knob 605 may be configured to adjust the groove depth in discrete value. For example, the depth tuning knob may be configured to adjust the groove depth in values of 0.010” per adjustment. However, values of more than 0.010” or less than 0.010” inches are also contemplated as required for a given application.

[0039] In some embodiments, the user may need to know to what groove depth to set groove roll 205. In such an embodiment, the user interface 130 may further include a depth indicator 617 configured to indicate whether the currently selected groove depth is deeper than a clampeddepth of a current pipe 200. The depth indicator 617 may output different colors and sequences of lights depending on the selected groove depth. The controller 700 may determine a clamped depth of the pipe 200 and compare the clamped depth to the selected groove depth. The depth indicator 617 may provide a first indication when the clamped depth is deeper than the selected groove depth and a second indication when the selected groove depth is too deep (e.g., deeper than the clamped depth). For example, the first indication may be a first color (e.g., green, blue, purple, etc.) continuously illuminated by the depth indicator 617 and the second indication may a second color (e.g., white, red, orange, etc.) illuminated by the depth indicator 617, which pulses on and off.

[0040] The speed selection knob 610 may be a knob with a selection indication that a user may radially move to select a grooving speed of the roll groover 100. For example, numbers (e.g., 0 - 10) may be evenly spaced around an outside circumference of the speed selection knob 610 on the housing 105 and a user may adjust the speed selection knob 610 to align the selection indication with the number that represents the speed the user desires. For example, a user may select a speed of a groove for a pipe of any size.

[0041] In some embodiments, the user interface 130 is illuminated. For example, an LED or LCD screen may be provided behind the power actuator 600, the depth tuning knob 605, and the speed selection knob 610 such that they are backlit and light radiates through space between the actuator and knobs and the housing 105. In some embodiments, the actuator and knobs themselves are illuminated.

[0042] The clamp status indicators 615 output different colors and sequences of lights depending on a clamp status. The controller 700 determines whether a pipe 200 is properly clamped based on a rotational position of the groove roll 305 and / or a power measurement at a motor 790, 795. For example, the rotational position of the groove roll 305 measures a clamp force on the pipe 200 based on the pipe wall thickness. The clamp status indicators 615 may provide a first indication when the pipe 200 is properly clamped to the roll groover 100, a second indication when the pipe 200 is improperly clamped (e.g., not fully clamped) to the roll groover 100, and a third indication before the roll groover 100 starts the grooving process. For example, the first indication may be a first color (e.g., green, blue, purple, etc.) continuously illuminated by the clamp status indicators 615, the second indication may a second color (e.g., white, red,orange, etc.) continuously illuminated by the clamp status indicators 615, and the third indication may be a third color (e.g., yellow, pink, etc.) that is incrementally illuminated by the clamp status indicators 615 (e.g., the third color is flashed for a predetermined amount of time).

[0043] A first bumper 620A is provided on a right side of the user interface 130 and a second bumper is provided on a left side of the user interface 130. The bumpers 620 provide protection so the power actuator 600, the depth tuning knob 605, and the speed selection knob 610 are not accidently contacted during the grooving process. The bumpers 620 may be made of a semi-soft material (e.g., silicone, soft plastic, etc.) or a hard material (e.g., metal, hard plastic, etc.).

[0044] FIG. 7 illustrates a block diagram of the roll groover 100. In the example illustrated, the roll groover 100 includes a controller 700 electrically and / or communicatively connected to a variety of modules or components of the roll groover 100. For example, the illustrated controller 700 is connected to a battery pack interface 705, a power input module 710, a FET switching module 715, one or more sensors 720, a work light 721, a jog trigger 722, a run switch 724, a capacitor 725, an inertial measurement unit 726, a transceiver 730, one or more indicators 735, and a user input module 740. The controller 700 includes combinations of hardware and software that are operable to, among other things, control operation of the roll groover 100, activate one or more indicators 735, monitor the operation of the roll groover 100, communicate with an associated external device (e.g., a smartphone) and the like.

[0045] In some embodiments, the controller 700 includes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the controller 700 and / or the roll groover 100. For example, the controller 700 includes, among other things, a processing unit 750 (e.g., a microprocessor, a microcontroller, an electronic processor, or another suitable programmable device), a memory 755, input units 760, and output units 765. The processing unit 750 includes, among other things, a control unit 770, an arithmetic logic unit (“ALU”) 775, and a plurality of registers 780 (shows as a group of registers in FIG. 7), and is implemented using a known computer architecture, such as a modified Harvard architecture, a von Neumann architecture, etc. The processing unit 750, the memory 755, the input units 760, and the output units 765 as well as the various modules connected to the controller 700 are connected by one or more control and / or data buses (e.g., a common bus 785). The control and / or data buses are shown generally in FIG.7 for illustrative purposes. The use of one or more control and / or data buses for the interconnection between and communication among the various modules and components would be known to a person skilled in the art in view of the invention described herein.

[0046] The memory 755 is a non-transitory computer readable medium and includes, for example, a program storage area and a data storage area. The program storage area and the data storage area can include combinations of different types of memory, such as read-only memory (“ROM”), random access memory (“RAM”) (e.g., dynamic RAM [“DRAM”], synchronous DRAM [“SDRAM”], etc.), electrically erasable programmable read-only memory (“EEPROM”), flash memory, a hard disk, an SD card, or other suitable magnetic, optical, physical, or electronic memory devices. The processing unit 750 is connected to the memory 755 and executes software instructions that are capable of being stored in a RAM of the memory 755 (e g., during execution), a ROM of the memory 755 (e.g., on a generally permanent basis), or another non- transitory computer readable medium such as another memory or a disc. Software included in the implementation of the roll groover 100 can be stored in the memory 755 of the controller 700. The software includes, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. The controller 700 is configured to retrieve from memory and execute, among other things, instructions related to the control processes and methods described herein. In other constructions, the controller 700 includes additional, fewer, or different components.

[0047] The battery pack interface 705 includes a combination of mechanical and electrical components configured to and operable for interfacing with the battery pack 126. For example, power provided by the battery pack 126 to the roll groover 100, is provided through the battery pack interface to a power input module 710. The power input module 710 includes combinations of active and passive components to regulate or control the power received from the battery pack 126 prior to power being provided to the controller 700. The battery pack interface 705 also supplies power to the FET switching module 715 to selectively provide power to a first motor 790 and a second motor 795. In some embodiments, the roll groover includes multiple independent FET switching bridges (e.g., including six FETs) in the FET switching module 715. The battery pack interface 705 also includes, for example, a communication line 796 for providing a communication line or link between the controller 700 and the battery pack 126.

[0048] The first motor 790 and the second motor 795 are, for example, brushless direct current (BLDC) motors. The first motor 790 is operated to move the groove roll 305 radially inward and outward. The first motor 790 may be controlled by the user using the jog trigger 722. The jog trigger 722 may be implemented as a trigger switch, a push button, a knob, or the like on the housing 105. When the user actuates the jog trigger 722, the controller 700 controls the FET switching module 715 to move the groove roll 305 radially inward or radially outward. The first motor 790 is coupled to the groove roll 305 using, for example, a feedscrew. The first motor 790 drives the feedscrew to produce movement in the groove roll 305. The FET switching module 715 includes a first H-bridge or a first inverter bridge used for controlling the first motor 790. The controller 700 provides PWM signals to the first H-bridge or the first inverter bridge to control the speed and direction of the first motor 790 based on signals received from the jog trigger 722 and a first rotary encoder 800 (shown in FIG. 8A). The direction of movement, that is, radially inward or radially outward, may be selected using a direction switch provided separately from the jog trigger 722. When the groove roll 305 is moved radially inward toward the inner roller 300, the groove roll 305 engages the pipe 200 to bite into the pipe 200. The jog trigger 722 may be operated until the groove roll 305 engages the workpiece. When the groove roll 305 is moved radially outward away from the inner roller 300, the groove roll 305 disengages the pipe 200 such that the roll groover 100 can be removed from the pipe 200. In some embodiments, the first motor 790 moves the inner roller 300 rather than the groove roll 305.

[0049] The second motor 795 is operated to move the roll casing 310 and the groove roll 305 circumferentially around the workpiece 200 to generate the groove in the workpiece 200. That is, the roll groover 100 or a portion of the roll groover 100 (e.g., the groove roll 305) moves around the pipe rather than the pipe turning within the tool. The second motor 245 is controlled by the user using the run switch 724. The run switch 724 may be implemented as a trigger switch, a push button, a knob, or the like. The run switch 724 may be the same as the power actuator 600. When the user actuates the run switch 724, the controller 700 controls the FET switching module 715 to move the roll casing 310 and the groove roll 305 around the track 315. The FET switching module 715 includes a second H-bridge or a second inverter bridge used for controlling the second motor 795. The controller 700 provides PWM signals to the second H- bridge or the second inverter bridge to control the speed and direction of the second motor 795based on the signals received from the run switch 724 and a second rotary encoder 805 (shown in FIG. 8A). The PWM signals provided to the second motor 795 may vary based on pipe thickness to control the roll groover 100 to complete a first pass of the pipe in a first predetermined amount of time regardless the pipe thickness. The direction of movement, that is, clockwise or anti-clockwise, may be selected using a direction switch provided separately from the run switch 724. The second motor 795 may move the roll casing 310 and the groove roll 305 in either direction to produce the groove in the pipe 200. In some embodiments, a single motor rather than the first motor 790 and the second motor 795 may be used to control both the radial movement and the circumferential movement of the groove roll 305. This can be achieved by using mechanical gears and clutching to shift the operation of the single motor between the different movements.

[0050] In some embodiments, several of the electrical components of the roll groover 100 are provided on one or more circuit boards (e.g., PCB 520). The circuit boards may, for example, be associated with the motors 790, 795, the jog trigger 722, the run switch 724, an on / off switch 743, a direction switch 741, a groove speed switch 742, stop switch(es) 744, and the battery pack interface 705. The one or more circuit board include a total surface area less than 155 squared centimeters (cm2) (24 in2). Specifically, the total surface are covered by the one or more circuit board includes electronic components for control of two motors 790, 795.

[0051] The work light 721 may be the same as the work light 145 and may provide illumination to a pipe 200. The capacitor 725 may store residual power to be used to remember a starting position of the roll groover 100 for a predetermined amount of time (e.g., 0 - 60 seconds) after the battery pack 126 is removed from the roll groover 100. For example, a user may wish to swap out a battery pack 126 of the roll groover 100 and the capacitor 725 will store enough charge for the controller 700 to store and retrieve a position of the groove roll 305 in the memory 755.

[0052] The transceiver 730 is operably coupled to the controller 700 to, for example, allow wired and / or wireless communication with an external device (e.g., a user’s smartphone, a connected display or control unit, and the like). The transceiver 730 allows the controller 700 to receive inputs from the external device and provide outputs for display on the external device. In some embodiments, the work light 721, the jog trigger 722, the run switch 724, the indicators735, and the user input module 740 may be implemented as inputs and / or outputs on the external device. The inputs from the external device are received through the transceiver 730 and the outputs to the external device are provided through the transceiver 730.

[0053] The user input module 740 is operably coupled to the controller 700 to, for example, select a direction of operation, a torque, and / or speed setting of the first motor 790 and / or the second motor 795. For example, the user input module 740 includes a direction switch 741 to select a direction of rotation of the groove roll 305, a groove speed switch 742 to set a speed of second motor 795 to control a speed of the groove roll 305, an ON / OFF switch 743 (e.g., power actuator 600) to turn the roll groover 100 on or off, and stop switch(es) 744 to halt operation of the motors 790, 795. In some embodiments, the user input module 740 includes a combination of digital and analog input or output devices required to achieve a desired level of operation for the roll groover 100, such as one or more knobs, one or more dials, one or more switches, one or more buttons, a touch screen, etc. In some embodiments, the jog trigger 722 and the run switch 724 are part of the user input module 740.

[0054] The indicators 735 include, for example, one or more light-emitting diodes (“LED”). The indicators 735 can be configured to display conditions of, or information associated with the roll groover 100. For example, the indicators 735 are configured to indicate that the groove roll 305 has reached a selected depth, the roll grooving operation is complete, and the like. In some embodiments, the indicators 735 may be part of a connected display or may be provided in an external device. For example, the indicators 735 may include the clamp status indicators 615.

[0055] Referring to FIG. 8A, the one or more sensors 720 includes a first rotary encoder 800, a second rotary encoder 805, a plurality of LiDAR (light detection and ranging) sensors 810, a temperature sensor 812, a groove depth sensor 820, a limit sensor 825, and a light level sensor 835. However, other sensor types may be used as required for a given application. The first rotary encoder 800 and the second rotary encoder 805 are, or use, for example, hall-effect sensors. The first rotary encoder 800 is provided on the first motor 790 to detect a rotary position of the first motor 790. The first rotary encoder 800 includes, for example, three Halleffect sensors placed 120 degrees apart. The first rotary encoder 800 divides the motor into six sectors (for example, 0-60°, 60-120°, 120-180°, 180-240°, 240-300°, 300-360°). A full mechanical rotation of the rotor includes movement of the rotor through these six sectors twice.Specifically, power flows through the six sectors to produce a force on the rotor to rotate the rotor within a stator. Thus, the rotary position of the rotor of the first motor 790 can be accurately sensed for every 12thof the circumference of the rotor. Additional Hall-effect sensors may be used to provide more granular measurements. Through the coupling of the rotor to a gearcase and a feedscrew, a linear equation directly ties the rotation of the rotor to the linear movement of the feedscrew. The rotary position of the motor and the linear equation can be used to accurately detect the linear position of the groove roll 305 and produce incremental movement of the groove roll 305.

[0056] The second rotary encoder 805 is provided on the second motor 795 to detect a rotary position of the second motor 795. The second rotary encoder 805 includes, for example, three Hall-effect sensors placed 120 degrees apart. The second rotary encoder 805 divides the motor into six sectors (for example, 0-60°, 60-120°, 120-180°, 180-240°, 240-300°, 300-360°). A full mechanical rotation of the rotor includes movement of the rotor through these six sectors twice. Specifically, power flows through the six sectors to produce a force on the rotor to rotate the rotor within a stator. Thus, the rotary position of the rotor of the second motor 295 can be accurately sensed for every 12thof the circumference of the rotor. Additional Hall-effect sensors may be used to provide more granular measurements. Through the coupling of the rotor to a gearcase and the groove roll 305, a linear equation directly ties the rotation of the rotor to the rotational movement of the groove roll 305 around the track 315. The rotary position of the motor and the linear equation can be used to accurately detect the rotational position of the groove roll 305 and produce movement of the groove roll 305 around the circumferential track 315.

[0057] The plurality of LiDAR sensors 810 are used to detect objects in the vicinity of the roll groover 100. During automated operation of the roll groover 100, the LiDAR sensors 810 may be used to detect obstructions or objects in the vicinity of the roll groover 100. Inductive sensor 815 may be mounted to the PCB 520 and may measure rotation of the eccentric grooving shaft 500.

[0058] The temperature sensor 812 may measure an ambient temperature of the roll groover 100 when the battery pack 126 is inserted. In one embodiment, the temperature sensor 812 is a thermistor, however, in other embodiments, the temperature sensor 812 may be any suitablesensor. The temperature sensor 812 may communicate to the controller 700 when the temperature is less than zero (0) degrees Celsius. Temperatures less than zero degrees Celsius may thicken grease within a gearbox of the roll groover 100, which may lower clamping forces. Accordingly, when the temperature sensor 812 communicates to the controller 700 that the temperature is less than zero degrees Celsius, the controller 700 may control the roll groover 100 to enter a low temperature mode. In the low temperature mode, clamp cut-off values (e.g., rotational position of the groove roll 305 and / or a power measurement at a motor 790, 795) may be increased by approximately 10% to compensate for the lower clamping force. For example, during the low temperature mode, the controller 700 may determine whether a pipe 200 is properly clamped based on a power measurement increased by 10% at a motor 790, 795.

[0059] The groove depth sensor 820 may measure a thickness of a pipe 200 to determine if the pipe 200 is the same thickness as a user input pipe thickness. The groove depth sensor 820 may be calibrated in a factory when the roll groover 100 is assembled. The calibration may be done using a vision measurement system, a handheld level, a coordinate measuring machine, or other measurement systems. Calibrating the groove depth sensor 820 ensures that every roll groover 100 acts the same.

[0060] The limit sensor 825 may be a sensor that a pipe 200 contacts when the pipe 200 is fully received by the roll groover 100. For example, the limit sensor 825 may communicate to the controller 700 that the pipe 200 is properly clamped to the roll groover 100. The limit sensor 825 may be a physical switch that is actuated by the pipe 200 when properly clamped. The capacitive touch sensor 830 may be provided on a wear plate 114 of the roll groover 100. For example, the wear plate may be provided at the first end 115 of the housing 105.

[0061] The light level sensor 835 may sense a level of ambient light around the roll groover 100. The light level sensor 835 may be one of a photoresistor, a photodiode, and a photo transistor. The sensed level of light may be used to determine whether the user interface 130 should be illuminated. The one or more sensors 720 may include additional sensors, for example, a current sensor, a voltage sensor, and the like.

[0062] The inertial measurement unit 726 is operably coupled to the controller 700 to, for example, provide heading, orientation, location, and movement information of the roll groover 100 to the controller 700. Referring to FIG. 8B, the inertial measurement unit 726 includes, forexample, a 9-axis inertial measurement sensor including a magnetometer 840, an accelerometer 845, and a gyroscope 850. The gyroscope 850 provides an orientation of the roll groover 100, the accelerometer 845 provides an angular position / velocity and a gravitational pull acceleration of the roll groover 100, and the magnetometer 840 provides a heading of the roll groover 100. The controller 700 uses the information received from the inertial measurement unit 726 to determine a position and / or orientation of the roll groover 100.

[0063] In some embodiments, the controller 700 may be configured to implement an overheat cooldown. For example, in response to the roll groover 100 performing multiple grooving processes in a hot environment, the roll groover 100 may enter the overheat cooldown and stop the user from grooving until the roll groover 100 has cooled down enough to not damage components. Different pipe sizes and wall thicknesses may require different amounts of energy to complete the grooving process. Accordingly, the overheat cooldown may be variable in time depending on the wall thickness and pipe size. For example, where the roll groover 100 completes five (5) grooving processes on small, thin walled pipes, the overheat cooldown may be a smaller amount of time than the overheat cooldown for completing five grooving processes on large, thick walled pipes.

[0064] FIGS. 9A and 9B are a flowchart of an example process 900 for performing a grooving process on pipes of different thicknesses. Although the illustrated process 900 includes specific steps, not all of the steps need to be performed or need to be performed in the order presented. The process 900 may be executed by the roll groover 100 (e.g., the controller 700 of the roll groover 100).

[0065] The process 900 includes determining that a first pipe 200 is received (step 905). The controller 700 may determine that the first pipe 200 is received based output from a sensor, such as sensors 720. For example, the controller 700 may determine that the first pipe 200 is contacting the limit sensor 825, that an electric field has changed due to the first pipe 200 contacting the capacitive touch sensor 830, and / or that a current draw has changed based on input from the current sensor. The first pipe 200 may be a first thickness in the range of 1.25 inches to 4 inches. The roll groover 100 is placed such that the inner roller 300 is received in the inner circumference of the pipe 200. The inner roller 300 supports the roll groover 100 on the pipe 200. Once the pipe 200 is received, the first motor 790 may move the groove roll 305toward the pipe 200. The controller 700 controls the first motor 790 using the FET switching module 715. The first motor 790 is controlled to move the groove roll 305 towards the inner roller 300. In some embodiments, the first motor 790 is used to move the inner roller 300 rather than the groove roll 305 to move the groove roll 305 toward the pipe 200.

[0066] The process 900 includes controlling the second motor 795 to rotate the roll groover 100 360° for a first amount of time (step 910). The second motor 795 moves the groove roll 305 around the first pipe 200. The controller 700 controls the second motor 795 using the FET switching module 715. In some embodiments, the controller 700 controls the FET switching module 715 using PWM signals. For example, using PWM signals, a drive output rotations per minute (RPM) of the second motor 795 may be a first value on the first pass. The second motor 795 is controlled to move the groove roll 305 around the track 315 and the pipe 200. The first amount of time may in the range of 0.1 seconds (“sec”) to 2 sec. In one example, the drive output speed may be in a range between 20 RPM and 70RPM. However, drive output speeds may also be less than 20 RPM or greater than 70 RPM. In other examples, the drive output speed may be based on the determined pipe diameter. For example, for pipes with diameters of 4” or greater, the drive output speed is approximately 60 RPM. However, drive output speeds of more than 60 RPM or less than 60 RPM are also contemplate as required for a given application. As the pipe diameters decrease, the drive output speed also decreases. For example, the drive output speed for a 3.5” diameter pipe may be 54 RPM, the drive output speed for a 3” diameter pipe may be 45 RPM, the drive output speed for a 2.5” diameter pipe may be 39 RPM, the drive output speed of a 2” diameter pipe may be 30 RPM, the drive output speed of a 1.5” diameter pipe may be 24 RPM, and the drive output speed of a 1.25” pipe may be 21 RPM. The above values represent drive output speed values according to one embodiment, and it is understood that other values may be used as required for a given application.

[0067] The process 900 includes increasing a speed of the second motor 795 a first predetermined amount (step 915). In some embodiments, the controller 700 may use PWM signals to provide a second RPM value to the second motor 795. For example, the second RPM value may be an incremental increase over the first value or may be a full speed value of the second motor 795.

[0068] The process 900 includes controlling the second motor 795 to rotate the roll groover 100 360° (step 920). The second motor 795 is controlled to move the groove roll 305 around the track 315 and the pipe 200 using the second RPM value.

[0069] The process 900 includes increasing a speed of the second motor 795 a second predetermined amount (step 925). In some embodiments, the controller 700 may use PWM signals to provide a third RPM value to the second motor 795. For example, the third RPM value may be an incremental increase over the second value. In the case that the second value was a full speed value, the second predetermined amount may be zero.

[0070] The process 900 includes controlling the second motor 795 to rotate the roll groover 100 continuously (step 930). The second motor 795 is controlled to move the groove roll 305 around the track 315 and the pipe 200 using the third RPM value. The second motor 795 may rotate the roll groover 100 for at least ten revolutions.

[0071] The process 900 includes finishing the roll grooving process on the first pipe 200 (step 940). The controller 700 may terminate the roll grooving process in response to rotating a predetermined number of times. In one embodiment, sensor data from sensors 720 may be used to determine the rotation of the first pipe 200 and provide the controller 700 with data to determine a number of rotations. In one example, the sensor may be a position sensor that detects a position of the roll groover 100 as it rotates around the first pipe 200. In one embodiment, the position sensor may be configured to determine a rotation within 10 degrees of a home position (i.e., a starting position). However, values of more than 10 degrees or less than 10 degrees are also contemplated. In an alternative embodiment, such as when the roll groover 100 is being operated in the “bench-top mode” a rotation of the second motor 795 may be sensed and used to determine a rotational position of the first pipe 200. For example, a hall-effect sensor as described above may provide an encoded count of the rotations of the second motor 795. However, other sensors 720 or processes may be used to determine the rotation of the second motor 795, as required for a given application. Alternatively, the controller 700 may terminate the roll grooving process in response to a groove being a first depth, as sensed by the groove depth sensor 820. The process 900 continues to FIG. 9B.

[0072] The process 900 includes determining that a second pipe 200 is received (step 945). For example, the controller 700 may determine that the second pipe 200 is contacting the limitsensor 825, that an electric field has changed due to the second pipe 200 contacting the capacitive touch sensor 830, and / or that a current draw has changed based on input from the current sensor. The second pipe 200 may be a second thickness in the range of 1.25 inches (“) to 4”. The second thickness may be greater than the first thickness. For example, the first thickness may be 1.25” and the second thickness may be over 2”. The roll groover 100 is placed such that the inner roller 300 is received in the inner circumference of the pipe 200. The inner roller 300 supports the roll groover 100 on the second pipe 200. Once the second pipe 200 is received, the first motor 790 may move the groove roll 305 toward the second pipe 200. The controller 700 controls the first motor 790 using the FET switching module 715. The first motor 790 is controlled to move the groove roll 305 towards the inner roller 300. In some embodiments, the first motor 790 is used to move the inner roller 300 rather than the groove roll 305 to move the groove roll 305 toward the second pipe 200.

[0073] The process 900 includes controlling the second motor 795 to rotate the roll groover 100 360° for the first amount of time (step 950). The second motor 795 moves the groove roll 305 around the second pipe 200. The controller 700 controls the second motor 795 using the FET switching module 715. In some embodiments, the controller 700 controls the FET switching module 715 using PWM signals. For example, using PWM signals, a drive output rotations per minute (RPM) of the second motor 795 may be a fourth value on the first pass. The second motor 795 is controlled to move the groove roll 305 around the track 315 and the second pipe 200. The fourth RPM value may be greater than the first RPM value in order to achieve a rotation of the roll groover 100 around the first pipe and the second pipe in a same amount of time, regardless of the difference in thickness of the pipes.

[0074] The process 900 includes increasing a speed of the second motor 795 to a top speed (step 955). In some embodiments, the controller 700 may use PWM signals to provide a fifth RPM value to the second motor 795. For example, the fifth RPM value may be a full speed RPM value.

[0075] The process 900 includes controlling the second motor 795 to rotate the roll groover 100 continuously until the grooving process on the second pipe 200 is done (step 960). The controller 700 may determine that the roll grooving process is done in response to rotating a predetermined number of times. Alternatively, the controller 700 may terminate the rollgrooving process in response to a groove of the second pipe 200 being a second depth, as sensed by the groove depth sensor 820.

[0076] FIG. 10 is a flowchart of a process 1000 for detecting an improper setting of the roll groover 100. Although the illustrated process 1000 includes specific steps, not all of the steps need to be performed or need to be performed in the order presented. The process 1000 may be executed by the roll groover 100 (e.g., the controller 700 of the roll groover 100).

[0077] The process 1000 includes receiving a user input pipe dimension (step 1005). A user may input dimensions (e g., a pipe thickness) of a pipe 200. The user may input the pipe thickness at the user interface 130. For example, the user interface 130 may include a knob that a user may adjust to select the thickness of the pipe 200. The controller 700 may save the user input pipe dimension in the memory 755.

[0078] The process 1000 includes receiving an actual pipe dimension from the groove depth sensor 820 (step 1010). The groove depth sensor 820 may measure a circumference of the pipe 200. For example, the controller 700 may control the second motor 795 to rotate the roll groover 100 around the pipe 200 without performing any grooving on the pipe 200 and the groove depth sensor 820 may measure the circumference while the roll groover 100 rotates. As explained above, a linear equation may be derived based on the connection between the second motor 295 and the groove roll 305. The distance traveled can then be calculated using the signals from the second rotary encoder 805 and the linear equation. The controller 700 may save the actual pipe dimension in the memory 755.

[0079] The process 1000 includes determining whether the user input pipe dimension is equal to the actual pipe dimension (decision step 1015). The controller 700 may compare the user input pipe dimension to the actual pipe dimension. When the user input pipe dimension is equal to the actual pipe dimension (“YES” at decision step 1015), the process 1000 proceeds to step 1020. When the user input pipe dimension is not equal to the actual pipe dimension (“NO” at decision step 1015), the process 1000 proceeds to step 1025.

[0080] The process 1000 includes initiating a grooving process (step 1020). The controller 700 may control the FET switching module 715 to operate the first motor 790 and the second motor 795 to perform the grooving process. In some embodiments, performing the grooving process includes determining, using the controller 700, that the pipe 200 is properly received bythe roll groover (e.g., as described below in FIG. 14), controlling, using the controller 700, the first motor 790 to move the groove roll 305 toward the pipe 200, determining, using the inertial measurement unit 726, an initial position of the groove roll 305, controlling, using the controller 700, the second motor 795, to move the groove roll 305 around the pipe 200 while measuring distance, determining, using the controller 700, whether the groove roll 305 has rotated 360°, controlling, using the controller 700, the second motor 795 to stop and record a measured distance, determining, using the controller 700, a groove depth based on the measured distance, and controlling, using the controller 700, the second motor 795 to move the groove roll 305 around the pipe 200 to provide grooving on the pipe 200.

[0081] The process 1000 includes preventing initiation of a grooving process (step 1025) in response to the user input pipe dimension not equaling the actual pipe dimension. For example, the controller 700 may send a “lock” instruction to the FET switching module 715 to not perform any switching and subsequently drive the motors 790, 795 where the actual pipe dimension does not equal the user input. They can help to prevent the roll groover 100 from potential failures where the user input pipe dimension is not equal to the actual pipe dimension because the controller 700 may fetch groove depths from the memory 755 and groove depths vary based on the circumference of the pipe 200 in the pipe fitting industry. Typically, a groove depth is standard for a particular dimension (e.g., thickness, circumference) of a pipe. The memory 755 may store a look-up table including a mapping between circumference dimension and the groove depth. The controller 700 can refer the look-up table stored in the memory 755 to find a groove depth that corresponds to a user input pipe dimension and use that groove depth for operation on the pipe 200.

[0082] FIG. 11 is a flowchart of a process 1100 for shutting off the roll groover 100 when the roll groover 100 is not rotating during a grooving process. Although the illustrated process 1100 includes specific steps, not all of the steps need to be performed or need to be performed in the order presented. The process 1100 may be executed by the roll groover 100 (e.g., the controller 700 of the roll groover 100).

[0083] The process 1100 includes initiating a grooving process (step 1105). The controller 700 may control the FET switching module 715 to operate the first motor 790 and the second motor 795 to perform the grooving process.

[0084] The process 1100 includes determining that the groove roll 305 is not rotating (step 1110). For example, the grooving process may be ongoing but the groove roll 305 and, therefore, the roll groover 100 may not be rotating about the pipe 200. The controller 700 may determine that the groove roll 305 is not rotating based on a sensed current draw on the groove roll 305, input from the inertial measurement unit 726, a groove on the pipe 200 not increasing in depth as sensed by the groove depth sensor 820, and the like.

[0085] The process 1100 includes shutting off the roll groover 100 (step 1115). For example, the controller 700 may disconnect the battery pack interface 705 from the FET switching module 715 so the motors 790, 795 no longer receive power. The roll groover 100 may potentially incur one or more faults where the groove roll 305 is not rotating while the grooving process is underway.

[0086] FIG. 12 is a flowchart of a process 1200 for shutting off the roll groover 100 when an input setting is changed during a grooving process. Although the illustrated process 1200 includes specific steps, not all of the steps need to be performed or need to be performed in the order presented. The process 1200 may be executed by the roll groover 100 (e.g., the controller 700 of the roll groover 100).

[0087] The process 1200 includes initiating a grooving process (step 1205). The controller 700 may control the FET switching module 715 to operate the first motor 790 and the second motor 795 to perform the grooving process.

[0088] The process 1200 includes determining that an input setting is changed during the grooving process (step 1215). For example, the controller 700 may determine that an input setting from one of the direction switch 741, the groove speed switch 742, the ON / OFF switch 743, and the stop switch 744 is changed. An input setting may be changed accidently or purposefully by a user. For example, a user may inadvertently bump the user interface 130 during the grooving process.

[0089] The process 1200 includes shutting off the roll groover 100 (step 1215) in the event that an input setting is changed during the grooving process. For example, the controller 700 may disconnect the battery pack interface 705 from the FET switching module 715 so the motors 790, 795 no longer receive power in response to the actual. The roll groover 100 shuts off toensure that the roll groover 100 does not start grooving while a user is changing settings if they have determined an issue with their initial settings.

[0090] FIG. 13 is a flowchart of a process 1300 for illuminating the user interface 130 the roll groover 100. Although the illustrated process 1300 includes specific steps, not all of the steps need to be performed or need to be performed in the order presented. The process 1300 may be executed by the roll groover 100 (e.g., the controller 700 of the roll groover 100).

[0091] The process 1300 includes receiving input from a light level sensor 835 (step 1305). The controller 700 receives input from the light level sensor indicative of an ambient level of light around the roll groover 100. For example, the controller 700 senses an increase in current that is proportional to a level of light sensed by the light level sensor 835.

[0092] The process 1300 includes determining that the input is below a first threshold value (step 1310). The controller 700 may compare the input from the light level sensor 835 to a first threshold value stored in the memory 755. For example, the controller 700 may compare a current level from the light level sensor 835 to a current level that is the first threshold value and determine that the current level from the light level sensor 835 is below the first threshold value.

[0093] The process 1300 includes illuminating the user interface 130 (step 1315). For example, an LED or LCD screen may be provided behind the power actuator 600, the depth tuning knob 605, and the speed selection knob 610 and they may be illuminated. In some embodiments, the actuator and knobs themselves are illuminated.

[0094] FIG. 14 is a flowchart of a process 1400 for detecting an insertion distance of a pipe 200 on the roll groover 100. Although the illustrated process 1400 includes specific steps, not all of the steps need to be performed or need to be performed in the order presented. The process 1400 may be executed by the roll groover 100 (e.g., the controller 700 of the roll groover 100).

[0095] The process 1400 includes receiving input from a first sensor 720 (step 1405). The first sensor may be a limit sensor 825, a capacitive touch sensor 830, or a current sensor. For example, the limit sensor 825 may be a switch that is provided on the workpiece interface 118 that is actuated when depressed by a pipe 200 received by the roll groover 100. As another example, the capacitive touch sensor 830 may be provided on the wear plate 114 or a point onthe inner roller 300 and the controller 700 may detect a change in an electric field when a pipe 200 contacts the capacitive touch sensor 830.

[0096] The process 1400 includes determining whether the pipe 200 is inserted a first distance on the roll groover 100 (decision step 1410). The first distance may be a distance with respect to the inner roller 300. For example, the first distance may be measured from the end of the inner roller not contacting the workpiece interface 118 to the workpiece interface 118. In other words, the controller 700 may determine whether the pipe is contacting the housing 105 of the roll groover 100 at the workpiece interface 118. The controller 700 may determine that the pipe 200 is contacting the limit sensor 825, that an electric field has changed due to the pipe contacting the capacitive touch sensor 830, and / or that a current draw has changed based on input from the current sensor. In response to the pipe 200 being inserted a first distance on the roll groover 100 (“YES” at decision step 1410), the process 1400 proceeds to step 1415. In response to the pipe 200 being determined to not be inserted the first distance on the roll groover 100 (“NO” at decision step 1410), the process 1400 proceeds to step 1420.

[0097] The process 1400 includes initiating the grooving process (step 1415). The controller 700 may control the FET switching module 715 to operate the first motor 790 and the second motor 795 to perform the grooving process.

[0098] The process 1400 includes controlling an indicator 735 to alert a user that the pipe 200 is not inserted the first distance (step 1420). The indicator 735 may be provided on the housing 105 and may illuminate in response to the pipe 200 not being inserted the first distance. For example, the indicator 735 may flash, illuminate while, or illuminate red.

[0099] FIG. 15 is a flowchart of a process 1500 for shutting off the roll groover in response to a safety actuator being actuated. Although the illustrated process 1500 includes specific steps, not all of the steps need to be performed or need to be performed in the order presented. The process 1500 may be executed by the roll groover 100 (e.g., the controller 700 of the roll groover 100).

[0100] The process 1500 includes receiving input from at least one stop switch 744 (step 1505). The controller 700 may receive an input signal from a stop switch 744. For example, the stop switch 744 may output a signal to the controller 700 in response to one of the first safety actuator 140 and the second safety actuator 150 is actuated by a user. A user may actuate thefirst safety actuator 140 and / or the second safety actuator 150 in a case of emergency, such as when they want an immediate shutdown of the roll groover 100, or inadvertently when they or another object is too close to the roll groover 100.

[0101] The process 1500 includes shutting off the roll groover 100 (step 1510). For example, the controller 700 may disconnect the battery pack interface 705 from the FET switching module 715 so the motors 790, 795 no longer receive power.

[0102] FIG. 16 is a flowchart of a process 1600 for outputting indications to an indicator 735 of the roll groover 100. Although the illustrated process 1600 includes specific steps, not all of the steps need to be performed or need to be performed in the order presented. The process 1600 may be executed by the roll groover 100 (e.g., the controller 700 of the roll groover 100).

[0103] The process 1600 includes receiving input from at least one sensor 720 (step 1605). The controller 700 may receive input from the groove depth sensor 820. For example, the controller 700 may control the second motor 795 to rotate the roll groover 100 around the pipe 200 without performing any grooving on the pipe 200 and the groove depth sensor 820 may measure the circumference while the roll groover 100 rotates to determine the pipe 200 thickness. In one embodiment, the wall thickness of the pipe 200 may be determined based on a difference between a measured outer diameter of the pipe 200 and an inner diameter of the pipe 200. For example, the inner diameter and outer diameter may be input via the user interface or sensed via one or more sensors 720 of the groove roller 100. As another example, the controller 700 may calculate the wall thickness of the pipe 200 based on input from the second rotary encoder 805.

[0104] The process 1600 includes determining a clamp force (step 1610). The controller 700 determines the clamp force based on the pipe thickness. In one embodiment, the controller 700 determines a power output of the groove roller based on a measured current draw and a measured battery pack 136 voltage. This power is then compared to a position of the groove roll 305. For example, the more engaged the groover die is, the smaller the pipe 200, and therefore the less power that is required to groove the pipe 200. In one example, the controller 700 may stop operation of the groove roller upon the power exceeding a predetermined threshold.

[0105] The process 1600 includes determining whether the pipe 200 is properly clamped to the roll groover 100 (decision step 1615). The controller 700 may compare the clamp force to apower measurement at the second motor 794 to determine whether the pipe 200 is properly clamped. For example, the controller 700 may determine how much power is being used by the second motor 795 and compare that to a threshold value proportional to a pipe thickness. The threshold value may be saved in the memory 755 of the controller 700 and may be factory set. In response to the controller 700 determining that the pipe 200 is properly clamped to the roll groover 100 (“YES” at decision step 1615; when the power measurement within a tolerance range of the threshold value), the process 1600 proceeds to step 1620. When the controller 700 determines that the pipe 200 is not properly clamped to the roll groover 100 (“NO” at decision step 1615; when the power measurement is outside a tolerance range of the threshold value), the process 1600 proceeds to step 1635.

[0106] The process 1600 includes controlling an indicator 615 to output a first indication (step 1620). The controller 700 may control the clamp status indicator 615 to output the first indication in response to the pipe 200 being properly clamped to the roll groover 100. For example, the first indication may be a first color (e.g., green, blue, purple, etc.) continuously illuminated by the clamp status indicators 615.

[0107] The process 1600 includes controlling the indicator 615 to output a second indication (step 1625). For example, the second indication may a second color (e.g., white, red, orange, etc.) continuously illuminated by the clamp status indicators 615.

[0108] The process 1600 includes initiating a grooving process (step 1630). The controller 700 may control the FET switching module 715 to operate the first motor 790 and the second motor 795 to perform the grooving process.

[0109] The process 1600 includes controlling the indicator 615 to output a third indication (step 1635). The controller 700 may control the clamp status indicator 615 to output the third indication in response to the pipe 200 being improperly clamped to the roll groover. For example, the third indication may be a third color (e.g., yellow, pink, etc.) that is incrementally illuminated by the clamp status indicators 615 (e.g., the third color is flashed for a predetermined amount of time).

[0110] FIG. 17 is a flowchart of a process 1700 for returning the roll groover 100 to a starting position. Although the illustrated process 1700 includes specific steps, not all of thesteps need to be performed or need to be performed in the order presented. The process 1700 may be executed by the roll groover 100 (e.g., the controller 700 of the roll groover 100).

[0111] The process 1700 includes determining that a first event is occurring (step 1705). The first event may be one of completing a grooving process and determining that the battery pack 136 is low. For example, the controller 700 may determine that the grooving process is complete based on a depth of a groove sensed by the groove depth sensor 820. The controller 700 may determine that the battery pack 136 is low based on data output from the battery pack 136 or a sensed decrease in current being output from the battery pack 136.

[0112] The process 1700 includes returning the groove roll 305 to a starting position (step 1710). The controller 700 may operate the FET switching module 715 to send a rotor of the second motor 795 to a first position that corresponds to the starting position of the groove roll 305. For example, the first position may be stored in the memory 755.

[0113] The process 1700 includes saving / storing the starting position for a first predetermined amount of time (step 1715). The controller 700 may use residual power stored in the capacitor 725 to remember the starting position. The first predetermined amount of time may be in the range of 0 - 60 sec. For example, the controller 700 may draw power from the capacitor 725 for 30 sec while a user swaps battery packs 126 and use the power to save the starting position of the groove roll 305 in the memory 755.

[0114] Thus, embodiments described herein provide, among other things, a roll groover for producing connection grooves on pipes.

Claims

CLAIMSWhat is claimed is:

1. A roll groover comprising: a housing; an inner roller provided on the housing and configured to be received in an inner circumference of at least one workpiece; a groove roll provided on the housing and configured to produce a groove on the at least one workpiece; a motor provided within the housing and configured to drive the groove roll; and an electronic processor electrically connected to the motor, the electronic processor configured to: determine that the inner roller receives a first workpiece having a first thickness, control the motor to rotate the roll groover a first distance around the first workpiece for a first predetermined amount of time, increase a speed of the motor, control the motor to rotate the roll groover continuously until a grooving process on the first workpiece is finished.

2. The roll groover of claim 1 , wherein the first distance is 360°.

3. The roll groover of claim 1, wherein the motor is configured to drive the roll groover circumferentially around the first workpiece.

4. The roll groover of claim 1, wherein the electronic processor is further configured to: determine that the inner roller receives a second workpiece having a second thickness, and control the motor to rotate the roll groover the first distance around the second workpiece for the first predetermined amount of time.

5. The roll groover of claim 4, wherein the first thickness is less than the second thickness.

6. The roll groover of claim 5, wherein the controller controls the motor to rotate the roll groover for the first predetermined amount of time around the first workpiece by using PWM to drive the motor at a first RPM value.

7. The roll groover of claim 6, wherein the controller controls the motor to rotate the roll groover for the first predetermined amount of time around the second workpiece by using PWM to drive the motor at a second RPM value.

8. The roll groover of claim 7, wherein the first RPM value is less than the second RPM value.

9. The roll groover of claim 1, wherein the controller determines that the grooving process on the first workpiece is finished in response to roll groover rotating a predetermined number of times.

10. The roll groover of claim 1, further comprising a battery pack configured to power the motor.

11. A method for detecting that a pipe is inserted a first distance on a roll groover, the method comprising: receiving, with a controller of the roll groover, an input from a sensor coupled to the roll groover, determining, with the controller of the roll groover, based on the input, that the pipe is inserted the first distance on the roll groover, and initiating, with the controller of the roll groover, a grooving process in response to the pipe being inserted the first distance on the roll groover.

12. The method of claim 11 further comprising: determining, with the controller of the roll groover, based on the input, that the pipe is not inserted the first distance on the roll groover, andcontrolling, with the controller, an indicator to alert a user that the pipe is not inserted the first distance.

13. The method of claim 11, wherein the sensor is one of a limit sensor, a capacitive touch sensor, and a current sensor.

14. The method of claim 13, wherein the limit sensor is actuated in response to the pipe depressing the limit sensor when the pipe is inserted the first distance on the roll groover.

15. The method of claim 13, wherein the capacitive touch sensor is provided on one of a wear plate of the roll groover and an inner roller of the roll groover, and wherein the controller detects a change in an electric field in response to the pipe contacting the capacitive touch sensor.

16. The method of claim 11, wherein initiating the grooving process includes: controlling, with the controller of the roll groover, a FET switching module to operate a first motor and a second motor.

17. The method of claim 16, wherein controlling the FET switching module to operate the first motor and the second motor includes: controlling, with the controller of the roll groover, the first motor to move a groove roll of the roll groover towards the pipe, determining, with an inertial measurement unit, an initial position of the groove roll, controlling, with the controller of the roll groover, the second motor to move the groove roll around the pipe while measuring a second distance, determining, with the controller of the roll groover, that the groove roll has rotated 360°, recording, with the controller, the second distance, determining, with the controller, a groove depth based on the measured distance, andcontrolling, with the controller, the second motor to move the groove roll around the pipe to provide grooving on the pipe.

18. The method of claim 16, wherein the controller uses PWM signals to control the FET switching module.

19. The method of claim 16, wherein the FET switching module includes a first H-bridge corresponding to the first motor and a second H-bridge corresponding to the second motor.

20. A system for measuring a groove depth on a pipe, the system comprising: a pipe; and a roll groover comprising: a housing, an eccentric grooving shaft, one or more sensors, a groove roll provided on the housing and configured to produce a groove on the Pipe, one or more motors provided within the housing and configured to drive the groove roll, and a controller electrically connected to the one or more motors and the sensor, the controller configured to: operate the one or more motors to perform a first operation of adjusting a groove depth on the pipe, operate the one or more motors to perform a second operation of producing the groove on the pipe, receive an input from the sensor, and determine a groove depth of the groove on the pipe based on the input from the sensor.

21. The system of claim 20, wherein a copper target is provided on the eccentric grooving shaft.

22. The system of claim 21, wherein the sensor senses a rotation of the eccentric grooving shaft by sensing a presence of the copper target.

23. The system of claim 22, wherein the sensor is an inductive sensor.

24. The system of claim 20, wherein the one or more sensors is stationary as the eccentric grooving shaft rotates.

25. A roll groover comprising: a housing; an inner roller provided on the housing and configured to be received in an inner circumference of a pipe; a groove roll provided on the housing and configured to produce a groove on the pipe; a motor provided within the housing and configured to drive the groove roll; and an electronic processor electrically connected to the motor, the electronic processor configured to: determine a pipe thickness of the pipe, determine a clamp force based on the pipe thickness, compare the clamp force to a power measurement of the motor, and determine that the pipe is properly clamped to the roll groover in response to the power measurement being within a tolerance range of a threshold value proportional to the pipe thickness.

26. The roll groover of claim 25, wherein the electronic processor is further configured to: control an indicator to output a first indication in response to the pipe being properly clamped, control the indicator to output a second indication, and initiate a grooving process.

27. The roll groover of claim 26, wherein the first indication includes the indicator continuously outputting a first color.

28. The roll groover of claim 27, wherein the second indication includes the indicator continuously outputting a second color.

29. The roll groover of claim 25, wherein the electronic processor is further configured to: determine that the pipe is not properly clamped to the roll groover in response to the power measurement being outside the tolerance range of the threshold value, and control an indicator to output an indication.

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