Extrusion Device Sagging Correction via Real-Time Wall Thickness Measurement
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Solution Overview
Problem
Existing methods fail to predict sagging accurately in tubular objects produced by extrusion devices, leading to inconsistent wall thickness and increased material usage, as sagging cannot be reliably measured or predicted until after complete solidification, causing delays and inefficiencies in the production process.
Innovation Solution
A device with first and second wall thickness measuring devices positioned upstream and downstream of cooling sections, respectively, with an evaluation device that compares delayed measurements to determine the sagging effect, allowing for real-time adjustment of the extrusion nozzle settings to achieve uniform wall thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If wall thickness is measured only after complete solidification, then measurement accuracy is improved, but production time is significantly delayed
Solution Approach 1:
The patent applies preliminary action by measuring wall thickness during the cooling process before complete solidification occurs. The system uses a measurement device that can detect wall thickness changes in real-time as the material transitions from molten to solid state, enabling early detection and adjustment without waiting for the entire cooling cycle to complete.
Solution Approach 2:
The patent implements feedback by continuously monitoring wall thickness during cooling and using this information to adjust extrusion parameters in real-time. The measurement device provides ongoing data about wall thickness variations, which the control system uses to modify extrusion speed, temperature, or other parameters to compensate for sagging and achieve uniform final wall thickness.
2Manufacturing precision
If extrusion nozzle is set with larger exit width in upper region to compensate for sagging, then wall thickness uniformity is improved, but material consumption increases
Solution Approach 1:
The patent uses real-time wall thickness measurements during cooling to provide feedback on actual sagging occurrence. This feedback enables the system to adjust extrusion nozzle settings dynamically based on measured deviations, rather than relying on fixed overcompensation, thereby reducing unnecessary material consumption while maintaining wall thickness uniformity.
Solution Approach 2:
The patent applies parameter changes by adjusting extrusion nozzle exit width and temperature parameters based on real-time measurement data. The system modifies these parameters during the extrusion process to compensate for measured sagging, optimizing material distribution to achieve uniform wall thickness without excessive material consumption.
3Manufacturing precision
If multiple corrections are made to achieve optimal process settings, then manufacturing precision is improved, but production duration is extended
Solution Approach 1:
The patent implements continuous feedback during the extrusion process by measuring wall thickness in real-time and adjusting parameters on-the-fly. This eliminates the need for multiple sequential corrections after production has started, as adjustments can be made continuously based on measured deviations, thereby reducing total production duration while maintaining precision.
Solution Approach 2:
The patent applies preliminary action by making real-time adjustments during the extrusion process itself rather than waiting for final measurement after cooling. This allows the system to correct deviations early in the process, reducing the number of iterative corrections needed and shortening the overall production cycle.
4Loss of time
If wall thickness is measured during cooling before solidification, then production time is reduced, but measurement accuracy is compromised
Solution Approach 1:
The patent replaces traditional mechanical measurement methods with optical or electromagnetic measurement techniques that can non-contactly detect wall thickness during cooling. These substitution methods enable accurate measurement of the cooling material without requiring it to be fully solidified, maintaining both speed and precision simultaneously.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables early prediction and correction of sagging, ensuring consistent wall thickness and reducing material waste by allowing for real-time adjustments during the production process, thereby improving the efficiency and accuracy of tubular object formation.
Implementation Method 1
a first wall thickness measuring device (24) for measuring the wall thickness of at least one wall of the tubular object (10) at a first measuring position
Implementation Method 2
a second wall thickness measuring device (25) for measuring the wall thickness of the at least one wall of the tubular object (10) at a second measuring position arranged downstream of the first measuring position in the conveying direction
Implementation Method 3
The tube is often cooled in the cooling sections using a cooling liquid, such as water. The cooling water flows around the tube and quickly hardens its outer area.
Implementation Method 4
In a first cooling section, the formed tube is prevented from collapsing, for example by means of a vacuum.
Implementation Method 5
there is sagging, i.e., the sinking of the still-flowing viscous mass fractions during solidification due to the influence of gravity
Data Source
Figure 1~2
AI summary
The invention relates to a device for checking the setting of an extrusion device that produces a tubular object conveyed in a conveying direction, wherein the extrusion device is set such that extruded material emerges with different exit widths from an upper and a lower side of an extrusion die of the extrusion device. The invention also relates to a corresponding method.