Open Seam Pipe Press Control Using Optical Gap Measurement
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Solution Overview
Problem
The existing bending press method for manufacturing steel pipes faces challenges in accurately controlling the seam gap between open seam edges, leading to inefficiencies in welding and potential damage due to excessive or insufficient punch pressing-down amounts, which are typically checked by human observation.
Innovation Solution
A bending press device equipped with an open seam edge measurement device that uses light projectors and receivers to monitor and control the seam gap, allowing for precise adjustment of the punch pressing-down amount based on measured data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the punch pressing-down amount is increased to reduce seam gap, then the seam gap control is improved, but the risk of damaging the pipe or punch support portion increases
Solution Approach 1:
The patent implements feedback control by measuring the actual seam gap after pressing and using this measurement to adjust the punch pressing-down amount for the next pressing operation. The measurement device detects the seam gap, and this information feeds back to the control system which automatically adjusts the pressing-down amount to maintain optimal seam gap control without causing pipe damage.
Solution Approach 2:
The patent dynamically changes the pressing-down amount parameter based on measured seam gap values. By adjusting this key parameter according to actual measurements rather than using fixed values, the system achieves precise seam gap control while avoiding excessive pressing that could damage the pipe or support portion.
2Device complexity
If human observation is used to check seam gap, then the device complexity is reduced, but the measurement precision deteriorates
Solution Approach 1:
The patent replaces the mechanical/human observation system with an optical measurement system. Light projectors and receivers are used to automatically measure the seam gap, substituting human eyes and manual measurement methods with precise optical instrumentation that provides objective, repeatable measurements.
3Manufacturing precision
If the punch pressing-down amount is excessively large, then the seam gap is reduced, but the productivity decreases due to pipe damage requiring cutting
Solution Approach 1:
The feedback mechanism prevents pipe damage by measuring seam gap and adjusting pressing-down amount accordingly, avoiding the need to cut damaged pipes and restart production. This continuous measurement and adjustment cycle maintains optimal pressing parameters, preventing defects that would reduce productivity.
Solution Approach 2:
The measurement and adjustment are performed before pipe damage occurs. By monitoring seam gap and adjusting pressing-down amount in advance, the system prevents the development of conditions that would lead to pipe damage and subsequent productivity loss from rework.
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 solution enhances manufacturing efficiency by accurately controlling seam gaps, preventing welding constraints and damage, and ensuring consistent pipe production.
Implementation Method 1
a light projector (4) which projects light toward the inside of the open seam pipe (3) through the seam gap (a)
Implementation Method 2
a light receiver (5) which receives the light projected by the light projector (4)
Implementation Method 3
control a punch pressing-down amount based on information measured by the measurement device
Data Source
Figure 1
Figure 2~3
Figure 4~5(c)
AI summary
Provided is a bending press device and a steel pipe manufacturing device where an amount of seam gap of an open seam pipe can be appropriately controlled. In a bending press device provided with an open seam edge measurement device where a punch pressing-down amount is set after measuring an amount of seam gap of an open seam pipe, the open seam edge measurement device includes a light projector and a light receiver mounted on the punch, a detection circuit and a control part. The open seam edge measurement device measures an amount of gap between a punch support portion and an open seam edge of an open seam pipe which is a material to be formed, and the punch pressing-down amount is controlled based on the measured amount of gap.