Groove Formation Device with Real-Time Diameter Control
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Solution Overview
Problem
The challenge in forming fluid-tight joints in pipe elements using mechanical couplings is exacerbated by the large dimensional tolerances of pipe elements, making it difficult to control the dimensions of circumferential grooves accurately during the cold working process, which affects the engagement with coupling keys and gasket compression.
Innovation Solution
A device comprising a drive roller, a grooving roller, and sensors to measure and control the groove diameter in real-time, using a control system to adjust the motion of the grooving roller based on feedback from sensors, ensuring the groove is formed within acceptable tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cold working is used to form grooves by forcing rollers against the pipe element, then the groove can be formed in the pipe element, but the large dimensional tolerances of the pipe element make it difficult to control the groove dimensions accurately
Solution Approach 1:
The system uses sensors to continuously monitor the groove diameter during formation and provides real-time feedback to the control system, which adjusts the roller position to maintain the groove within specified dimensional tolerances despite variations in pipe element dimensions
Solution Approach 2:
The system transitions from a static, fixed-position roller approach to a dynamic system where the roller position is continuously adjusted based on real-time measurements of the groove diameter and pipe element dimensions, enabling accurate groove formation despite dimensional variations
2Ease of manufacture
If the groove dimensions are not precisely controlled, then the manufacturing process is simpler, but the engagement with coupling keys and gasket compression is compromised
Solution Approach 1:
Real-time sensor feedback on groove diameter enables the control system to maintain precise groove dimensions, ensuring reliable engagement with coupling keys and proper gasket compression while keeping the manufacturing process automated and consistent
Solution Approach 2:
The system replaces manual trial-and-adjustment procedures with an automated control system that uses sensor feedback to precisely control groove formation, ensuring reliable joint performance without requiring manual intervention
3Manufacturing precision
If real-time measurement and control is implemented during groove formation, then groove dimensional accuracy is improved, but the device complexity increases
Solution Approach 1:
The control system processes sensor signals to determine groove diameter and automatically adjusts roller position, providing precise dimensional control through a closed-loop feedback mechanism that manages the complexity through automation
4Productivity
If the groove diameter is not accurately controlled, then the manufacturing process is faster, but the frequency of malformed grooves increases
Solution Approach 1:
The real-time feedback system continuously monitors groove formation and makes immediate adjustments to prevent malformation, maintaining high groove quality without requiring slow, manual inspection and correction procedures
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
This method allows for precise control of groove formation, reducing human error and the frequency of malformed grooves, ensuring proper engagement with coupling keys and effective gasket compression for a fluid-tight seal, even with pipes having varying dimensions within large tolerances.
Implementation Method 1
a drive roller rotatable about a drive roller axis... engageable with an inner surface of the pipe element
Implementation Method 2
a grooving roller... movable toward and away from the drive roller so as to forcibly engage an outer surface of the pipe element so as to displace material of the pipe element and form the groove
Implementation Method 3
an idler roller... engageable with an outer surface of the pipe element so as to rotate upon rotation of the pipe element
Data Source
Figure 1
Figure 1A
Figure 2
AI summary
The invention encompasses a device for forming a circumferential groove in a pipe element having a longitudinal axis. In an example embodiment, the device comprises a drive roller rotatable about a drive roller axis. The drive roller is engageable with an inner surface of the pipe element when the drive roller axis is oriented substantially parallel to the longitudinal axis of the pipe element. A grooving roller is rotatable about a grooving roller axis oriented substantially parallel to the drive roller axis. The grooving roller is movable toward and away from the drive roller so as to forcibly engage an outer surface of the pipe element so as to displace material of the pipe element and form the groove therein upon rotation of the pipe element. An idler roller is rotatable about an idler roller axis oriented substantially parallel to the drive roller axis. The idler roller has a known diameter. The idler roller is movable toward and away from the drive roller so as to engage an outer surface of the pipe element so as to rotate upon rotation of the pipe element. A first sensor determines a degree of rotation of the idler roller and generates a first signal indicative thereof. A second sensor determines a degree of rotation of the pipe element and generates a second signal indicative thereof. A control system is adapted to receive the first and second signals and use the first and second signals to determine a diameter of the groove, and control motion of the grooving roller toward and away from the drive roller in response to the diameter of the groove.