Deburring detection system and method

Abstract

The present invention relates specifically to a deburring damage detection system and a deburring damage detection method for this system, which enables the instantaneous detection of breakage and dulling of the cutting tool / blade on the deburring apparatus used to clean the burrs formed inside the pipe after the high-frequency welding process in pipe production, and allows for rapid intervention in the system to remedy the damage, thus preventing faulty or incomplete operations.

Description

[0001] DESCRIPTION

[0002] DEBURRING DETECTION SYSTEM AND METHOD

[0003] Field of the Invention

[0004] The present invention relates to a deburring damage detection system and method that enables the instantaneous detection of breakage and dulling of the deburring blade, which is used to clean the burrs formed after the welding process in pipe production, and allows for rapid intervention in the system.

[0005] The present invention relates specifically to a deburring damage detection system and a deburring damage detection method for this system, which enables the instantaneous detection of breakage and dulling of the cutting tool / blade on the deburring apparatus used to clean the burrs formed inside the pipe after the high-frequency welding process in pipe production, and allows for rapid intervention in the system to remedy the damage, thus preventing faulty or incomplete operations.

[0006] State of the Art

[0007] Automatic high-frequency welding is particularly used in the production of welded pipes (Electric Resistance Welded - ERW). After this welding process, burrs form at the weld line inside the pipe, and a device called a deburring tool is used to clean these burrs while the process continues. Using the cutting tool / blade / pen (impeder tool) on the deburring apparatus, the burr produced after welding is mechanically scraped / cut from the inner surface of the pipe while the welding process is in progress. However, during this process, if the cutting tool / blade in the deburring apparatus becomes dull over time or breaks inside the pipe, the burrs formed during the welding process cannot be removed, and the production process is completed with the burrs still inside the pipe. Due to the rapid pace of the welding process, it takes time for the operator to notice any errors or damage to the cutting tool inside the pipe, and during this time, meters of pipe are produced defectively without the internal burrs being removed. In this case, pipes with burrs remaining after the welding process need to be returned to the line and the burrs need to be reground by the operator / user. In this grinding process, a single operator can clean approximately 3 pipes in 8 hours, which significantly reduces the time required to grind thousands of burr-covered, second-grade pipes produced during mass production, resulting in high costs, labor, energy, and time losses. Furthermore, if the number of pipes with internal burrs to be ground is large, the grinding process takes a long time to complete, and as a result, the pipes waiting to be processed rust over time, leading to product loss. In addition, inhaling the iron dust producedduring the grinding process, the ergonomic difficulty of grinding inside the pipe, the noise of the process, and the high vibrations generated negatively affect the operator's health.

[0008] The utility model document numbered CN220463274U, which is included in the known state of the art, describes a device designed to remove burrs from the end surfaces of metal pipes. This device consists of components such as the feed rail, machine body, and collection hopper. The rotating disc and protective cover mounted on the machine body ensure the efficient operation of the device. In addition, a pneumatic turntable is installed on the lower wall of the protective cover. This device quickly removes burrs from the ends of pipes, while the pipe is firmly gripped by halfring clamping blocks, preventing the sanding disc from breaking and damaging it due to vibration. This extends the life of the sanding disc. The device can operate continuously throughout the day without requiring any manual intervention, simply by regularly changing the collection chamber. With the help of the discharge mechanism, the pipes do not have to be manually removed from inside the rotating disc. The document does not disclose any solution for the real-time detection of breakage or wear of the deburring blade used to remove burrs inside the pipe, or for generating an alert upon detection.

[0009] Another patent document, numbered CN109759917A, belonging to the state of the art, describes a deburring device for hypoid gears in the field of gear machining. This device comprises an ultrasonic grinding system and a grinding material suspension fluid circulation system. The ultrasonic grinding system comprises an ultrasonic vibration system and a tool head. In the system, a holding cavity compatible with the gear to be machined is created at one end. A liquid inlet hole connected to the holding cavity is located in the tool head. This inlet hole connects to a circulation pump and a connecting pipe, enabling the transport of fluid. The ultrasonic grinding system is positioned to be compatible with the entire head of the gear, thus ensuring that all teeth of the gear are machined correctly. In the grinding system, the suspension fluid increases machining efficiency by continuously feeding the circulation system. The document does not disclose any solution for the real-time detection of breakage or wear of the deburring blade used to remove burrs inside the pipe, or for generating an alert upon detection.

[0010] In conclusion, there is a need to develop a deburring damage detection system and a deburring damage detection method for this system, which would enable the rapid and instantaneous detection of breakage and dulling of the cutting element in the deburring apparatus used to remove burrs from inside the pipe during high-frequency welding, especially in welded pipe production, and would warn the operator and stop the welding process to prevent continued production with internal pipe burrs.Object of the Invention

[0011] The present invention relates to a deburring damage detection system and method with distance adjustment which fulfils the abovementioned requirements, eliminates all disadvantages and brings some additional advantages.

[0012] The main object of the deburring damage detection system and method described in the present invention is to develop a deburring damage detection system and method that enables the instantaneous detection of damage and dulling of the cutting element responsible for cleaning the burrs formed inside the pipe during the welding process.

[0013] Another object of the present invention is to develop a deburring damage detection system and method that alerts the operator / user without delay if damage or dulling of the cutting element is detected.

[0014] Another object of the present invention is to obtain an effective deburring damage detection system and method that prevents the pipe from being manufactured with burrs inside if damage or dulling of the cutting element is detected, and allows the welding process to be stopped in order to repair the damaged or blunt cutting element.

[0015] Another object of the present invention is to obtain an efficient deburring damage detection system and method that prevents faulty / defective production, thereby reducing production costs, product, energy and labor losses, and processing time.

[0016] Another object of the present invention is to obtain an effective deburring damage detection system and method that protects operator health and improves product quality by eliminating the need for operator-side grinding after the welding process.

[0017] Another object of the present invention is to obtain a functional deburring damage detection system and method that improves process quality and final product integrity.

[0018] An alternative object of the present invention is to obtain an easy-to-use and functional deburring damage detection system and method suitable for use in welding pipes of different sizes and types.

[0019] To achieve the above objectives in the most general terms, a deburring damage detection system is required, which comprises at least one cutting element and at least one hanging apparatus forcleaning the burrs formed inside the pipe during the welding process, is suitable for use with at least one internal deburring apparatus for smoothing the inner surface of the pipe, and provides a warning system for detecting damage and dulling of the cutting element and alerting the operator / user, comprising at least one sensing element; at least one connecting element; at least one transmission element; at least one control element; and at least one informing element.

[0020] The deburring damage detection system developed with the present invention and the deburring damage detection method suitable for use, comprising the steps of; detecting vibration intensity values and transmission the detected vibration data as an analog signal; converting and transmitting analog signals containing the received vibration data into digital signals; processing vibration data and determining the normal vibration range and threshold value; detecting the presence of abnormal vibration levels and determining whether damage or deterioration has occurred if the vibration level variation is greater than the threshold value in the vibration data; sensing visual and / or auditory information about the amount of abnormal vibration and the extent of damage to the operator / user.

[0021] The structural and characteristic features of the present invention will be understood clearly by the following drawings and the detailed description made with reference to these drawings and therefore the evaluation shall be made by taking these figures and the detailed description into consideration.

[0022] Figures Clarifying the Invention

[0023] In order to understand the advantages of the present invention with its structure and additional elements, it shall be evaluated with the following defined figures.

[0024] Figure - 1: A perspective view of the fastening element in the deburring damage detection system of the present invention.

[0025] Figure - 2: A perspective view of the sensing and fastening element in the deburring damage detection system of the present invention.

[0026] Figure - 3: A schematic view of the deburring damage detection system of the present invention.

[0027] Part References

[0028] 1. Sensing element

[0029] 2. Fastening element

[0030] 3. Transmission element4. Control element

[0031] 5. Informing element

[0032] 6. Storage unit

[0033] A. Hanging apparatus

[0034] B. Deburring apparatus

[0035] Detailed Description of the Invention

[0036] In this detailed description, the preferred alternatives of the deburring damage detection system and method is described only for clarifying the subject matter such that no limiting effect is created.

[0037] The deburring damage detection system, the example appearance of which is given in Figure 1, which is developed with the present invention and enables the removal of burrs formed inside the pipe during the welding process in pipe production by scraping / cutting, and comprises at least one cutting element, preferably in the form of a blade, and at least one hanging apparatus (A) that connects the cutting element to the deburring apparatus (B), and is suitable for use with at least one internal deburring apparatus (B) that smooths the inner surface of the pipe, and enables the instantaneous detection of damage and dulling of the cutting element and the immediate warning of the operator / user, comprising the following; at least one sensing element (1) which is a 3-axis microelectromechanical system (MEMS) type accelerometer or vibration sensor, positioned close to the cutting element, which enables the detection of the amount of vibration generated on the cutting element during the internal burr removal process and the transmission of the detected vibration amount data; at least one fastening element (2) which is fixed to the hanging apparatus (A), which enables the sensing element (1) to be attached to the internal deburring apparatus (B) close to the cutting element and helps to transmit the vibration generated on the cutting element to the sensing element (1); at least one transmission element (3) connected to the sensing element (1) and enabling the conversion of the analog signal of the vibration data from the sensing element (1) into a digital signal, preferably an analog-to-digital converter (ADC); at least one control element (4) connected to the transmission element (3), which enables the processing of the digital signal data sent from the transmission element (3) and the monitoring of the vibration data, obtaining a vibration amount threshold value using the monitored vibration data with at least one mathematical algorithm running on it, and stopping the source process by detecting the presence of an anomaly if the vibration amount exceeds the threshold value, preferably suitable for running the Fast Fourier Transform (FFT) algorithm for analysis and threshold value determination, preferably a processor or circuit board; at least one informing element (5) connected to the control element (4) which provides the user with information and / or a visualand / or audible warning in case of detection of an abnormal situation, preferably including at least one screen.

[0038] In an embodiment of the deburring damage detection system developed with the present invention, the cutting element, which enters the pipe during the welding process and cleans the burr formed inside the pipe by scraping or cutting, is connected to the internal deburring apparatus (B) via a hanging apparatus (A). The sensing element (1) is fixed onto the hanging apparatus (A) by means of the fastening element (2), ensuring that the sensing element (1) accurately and precisely detects the amount of vibration generated on the cutting element. Firstly, during the initial operation of the system under normal conditions, the vibration (acceleration) values generated on the cutting element, preferably on three different axes, are detected by the sensing element (1) at intervals of preferably 1 millisecond, and the detected vibration amount data is transmitted as an analog signal. Analog signals containing vibration data received from the sensing element (1) are converted into digital signals via the transmission element (3) and transmitted to the control element (4). Vibration amount data of the initial operation of the system are processed via the control element (4) and, preferably by processing via the Fast Fourier Transform (FFT) algorithm, the normal vibration amount range and the threshold value defining the acceptable maximum vibration magnitude which shows that the process is error-free are determined. Data obtained during the welding and scrapping process are analyzed and recorded using at least one machine learning algorithm (such as K-Nearest Neighbor (KNN)) which is run on the control element (4). During the process, if the vibration amount data, detected by the sensing element (1) and transmitted to the control element (4), shows a change greater than the defined threshold value, the control element (4) detects the presence of an abnormality and decides that there is a possible damage or dulling of the cutting element. Afterwards, this abnormal situation information is communicated to the informing element (5). Thus, the operator / user is provided with visual and / or auditory information about the detected abnormal situation and possible damage situation through the informing element (5). Meanwhile, in order to prevent the deburring process from continuing with a damaged or blunt cutting element, the welding process is stopped by means of the control element (4).

[0039] The sensing element (1) performs a vibration detection every 1 millisecond, as defined by the following processes:

[0040] Sampling Speed Calculation:

[0041] Sampling frequency: 1000 Hz

[0042] Total data processed per second: 1000 samples.Sampling Frequency Calculation:

[0043] To process data at 1 ms intervals, the sensor's sampling frequency must be:

[0044] fs= - Ts= — 0,001 = 1000 Hz ( '1 kHz) '

[0045] However, high-frequency vibration analysis typically requires sampling rates of 20 kHz or higher. According to Nyquist's Theorem, the minimum sampling frequency fmaxrequired for the target frequency is:

[0046] f

[0047]

[0048] max 2 * fmax

[0049] For an analysis with a 10 kHz upper limit:

[0050] fs> 2 * 10kHz = 20kHz

[0051] This requires acquiring and processing 20 data points every 1 ms.

[0052] T =

[0053]

[0054] 1s

[0055] fs=20kHz i in Ts=0,05ms.

[0056] Sampling Time Calculation:

[0057] T =

[0058]

[0059] 1s

[0060] fs=20kHz i in Ts=0,05ms.

[0061] Processing Time Calculation:

[0062] The total time for data acquisition and processing should be less than 1 ms:

[0063] T1processing ^sampling T ^analysis• Sampling time Tsampling, depends on the ADC speed.

[0064] • Analysis time Tanalysisdepends on processor performance and algorithm efficiency.

[0065] FFT and Vibration Analysis:

[0066] • The processing time for the FFT can be calculated using the formula: TFFT=O(n log n), where n is the number of data points.

[0067] For n=2000 data points, processing time is optimized depending on the processor.

[0068] For example, in detecting abnormal vibration levels:

[0069] In an example graphical structure used on the operator screen:

[0070] • X axis: Time (milliseconds)

[0071] • Y axis: Vibration Amplitude (m / s2)

[0072] Sample data:

[0073] Time (ms) Vibration magnitude (m / s2) Threshold Value (m / s2)

[0074] 0 0.1 0.30

[0075] 1 0.15

[0076] 2 0.20

[0077] 3 0.50 (Thresholdexceeded.)

[0078] In a preferred embodiment of the present invention, the aforementioned deburring damage detection system comprises at least one storage unit (6) which enables the storage of the vibration quantity data from the aforementioned sensing element (1) and the data obtained after the analysis performed on the aforementioned control element (4), which is connected to the aforementioned control element (4). In this way, vibration amount data obtained from analyses performed on different sizes and pipe types can be recorded and used in subsequent analyses and machine learning processes.

[0079] In another preferred embodiment of the present invention, the aforementioned deburring damage detection system comprises at least one data transmission element, preferably in a cable structure, which enables the transfer of vibration quantity data between the system elements,connected to the aforementioned sensing element (1), transmission element (3) and control element (4).

[0080] In another preferred embodiment of the invention, the aforementioned deburring damage detection system comprises at least one insulation element, preferably in a heat-insulated sheath structure, which is located on the aforementioned sensing element (1) and the data transmission element, and which prevents the aforementioned sensing element (1) from being affected by the heat generated inside the pipe during the process.

[0081] The deburring damage detection system developed with the present invention and the deburring damage detection method suitable for use, comprising the steps of; during the first deburring operation of the internal deburring apparatus (B), detecting the vibration amount (acceleration) values from at least 20 different positions on the cutting element in three different axes, preferably at 1 millisecond intervals, by means of the sensing element (1) in order to increase the data acquisition sensitivity (data acquisition at frequent intervals) and the data of the detected vibrations are transmitted as an analog signal; converting the analog signals containing the vibration data received from the sensing element (1) into digital signals via the transmission element (3) and transmitting the same to the control element (4); processing the vibration data of the first deburring operation through the control element (4) using the Fast Fourier Transform (FFT) algorithm and determining the threshold value that defines the normal vibration amount range and the maximum vibration amount value for the operation to be considered error-free; determining the normal vibration range and threshold value, independent of pipe type and size by analyzing the data obtained during the welding and deburring process, preferably with at least one machine learning algorithm, preferably the K-Nearest Neighbor (KNN) algorithm, which is run on the control element (4); If the vibration amount data transmitted to the control element (4) by sensing element (1) shows a vibration change greater than the threshold value, detecting the presence of an abnormal vibration amount and deciding that there is possible damage or blunting in the cutting element by the control element (4); transmitting the information regarding the amount of abnormal vibration and the condition of damage transmitted from the control element (4) to the operator / user visually and / or audibly via the information element (5); If abnormal vibration levels are detected, preferably to prevent the deburring process from continuing with a damaged or blunt cutting element, stopping the welding process by means of the control element (4).

[0082] With the deburring damage detection system and method developed with the present invention, it is possible to detect the fracture and bluntness of the cutting element in the deburring apparatus (B), which cleans the burrs formed inside the pipe during the pipe welding process, with precisionand instantaneous accuracy. Furthermore, an effective, efficient, and reliable deburring damage detection system and a deburring damage detection method developed for the operation of this system are obtained, which enables the operator / user to be quickly alerted in case of detection of damage or blunting, and prevents the welding process from continuing with defective production without cleaning the internal burrs of the pipe, thus reducing workload and costs.

Claims

CLAIMS1. A deburring damage detection system that comprises at least one cutting element that enables the removal of burrs formed inside the pipe during the welding process in pipe production by scraping / cutting, and at least one hanging apparatus (A) that connects the cutting element to the apparatus, and is suitable for use with at least one internal deburring apparatus (B) that ensures the smoothing of the inner surface of the pipe, wherein the system enables the instantaneous detection of damage and dulling of the cutting element and the immediate warning of the operator / user, comprising:at least one sensing element (1) which enables the detection of the amount of vibration generated on the cutting element during the internal burr removal process and the transmission of the detected amount of vibration data, wherein the sensing element (1) is positioned close to the cutting element;at least one fastening element (2) which enables the sensing element (1) to be attached to the internal deburring apparatus (B) in close proximity to the cutting element and helps to transmit the vibration generated on the cutting element to the sensing element (1), wherein fastening element (2) is fixed to the hanging apparatus (A);at least one transmission element (3) connected to the sensing element (1) and converts the analog signal of the vibration data from the sensing element (1) into a digital signal;at least one control element (4) which enables the processing of the digital signal data sent from the transmission element (3) and the monitoring of the vibration data, obtaining a vibration amount threshold value using the monitored vibration data with at least one mathematical algorithm working thereon, and stopping the source process by detecting the presence of an anomaly if the vibration amount exceeds the threshold value, control element (4) is connected to the transmission element (3);at least one informing element (5) that is connected with the control element (4) and warns the user with information, visually and / or audibly if an abnormal situation is detected.

2. A deburring damage detection system according to claim 1, wherein the cutting element is in the form of a blade.

3. A deburring damage detection system according to claim 1, wherein the sensing element (1) is a 3-axis microelectromechanical system (MEMS) type accelerometer or vibration sensor.

4. A deburring damage detection system according to claim 1, wherein the transmission element (3) is an analog-to-digital converter.

5. A deburring damage detection system according to claim 1, wherein the control element (4) is suitable for running the Fast Fourier Transform (FFT) algorithm for analysis and threshold value determination.

6. A deburring damage detection system according to claim 1, wherein the control element (4) is a processor or a circuit board.

7. A deburring damage detection system according to claim 1, wherein the informing element (5) comprises at least one screen.

8. A deburring damage detection system according to claim 1, wherein the system also comprises at least one storage unit (6) which enables the storage of the vibration quantity data from the aforementioned sensing element (1) and the data obtained after the analysis performed on the aforementioned control element (4), wherein the storage unit (6) is connected to the aforementioned control element (4).

9. A deburring damage detection system according to claim 1, wherein the system also comprises at least one data transmission element, preferably in a cable structure, which enables the transfer of vibration quantity data between the system elements, connected to the sensing element (1), the transmission element (3) and the control element (4).

10. A deburring damage detection system according to claim 9, wherein the system also comprises at least one insulation element, preferably in a heat-insulated sheath structure, which is located on the aforementioned sensing element (1) and the data transmission element, and which prevents the aforementioned sensing element (1) from being affected by the heat generated inside the pipe during the process.

11. A method of using a deburring damage detection system according to any one of the preceding claims, comprising steps of:during the first deburring operation of the internal deburring apparatus (B), detecting vibration levels at at least 20 different locations on the cutting element along threedifferent axes and transmitting the detected vibration data as an analog signal through the mentioned sensing element (1) to increase the sensitivity of data acquisition;- converting the analog signals containing the vibration data received from the sensing element (1) into digital signals via the transmission element (3) and transmitting the same to the control element (4);- processing the vibration data of the first deburring operation through the control element (4) using the Fast Fourier Transform (FFT) algorithm and determining the threshold value that defines the normal vibration amount range and the maximum vibration amount value for the operation to be considered error-free;- detecting the presence of an abnormal vibration amount and deciding that there is possible damage or blunting in the cutting element by the control element (4), if the vibration amount data transmitted to the control element (4) by sensing element (1) shows a vibration change greater than the threshold value;- transmitting the information regarding the amount of abnormal vibration and the condition of damage transmitted from the control element (4) to the operator / user visually and / or audibly via the informing element (5).

12. A deburring damage detection method according to claim 11, wherein the method comprising the step of detecting vibration level values at 1 -millisecond intervals.

13. A deburring damage detection method according to claim 11, wherein the method comprising the step of determining the normal vibration range and threshold value, independent of pipe type and size by analyzing the data obtained during the welding and deburring process, preferably with at least one machine learning algorithm, preferably the K-Nearest Neighbor (KNN) algorithm, which is run on the control element (4).

14. A deburring damage detection method according to claim 11, wherein the method comprising the step of stopping the welding process by means of the control element (4), in case abnormal vibration levels are detected, preferably to prevent the deburring process from continuing with a damaged or blunt cutting element.

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