Pipe Bender Handle Angle Sensing for Calibration-Free Bending
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Solution Overview
Problem
Existing pipe benders require time-consuming calibration and effort to achieve accurate bends, and existing devices for determining bend angles are not always precise or user-friendly.
Innovation Solution
A sensor and display system is integrated into a pipe bender handle to provide real-time feedback on the orientation angle, using sensors like accelerometers and gyroscopes, and can be securely affixed to the handle, eliminating the need for calibration and enhancing precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If traditional pipe benders are used without integrated sensors, then the device structure remains simple, but calibration time and user effort increase significantly
Solution Approach 1:
The patent combines the sensor system, processor, and display into an integrated unit that attaches to the pipe bender handle. This merging of components eliminates the need for separate calibration devices and procedures, reducing calibration time while keeping the overall system complexity manageable through modular integration.
Solution Approach 2:
The sensor system automatically measures the orientation angle of the pipe bender and provides real-time feedback without requiring user calibration or intervention. The processor continuously calculates the bend angle based on sensor data and displays it automatically, making the system self-calibrating and eliminating time-consuming manual calibration steps.
2Measurement precision
If mechanical protractors are used to measure bend angles, then the device remains simple, but measurement precision and accuracy are insufficient
Solution Approach 1:
The patent replaces mechanical protractors and physical alignment tools with electronic sensors (accelerometers and/or gyroscopes) that digitally measure the orientation angle. This substitution provides significantly higher measurement precision and accuracy while the modular sensor attachment keeps the overall device complexity manageable.
Solution Approach 2:
The system continuously monitors the bend angle through sensors and provides real-time feedback via display to the user. This closed-loop feedback mechanism enables precise measurement and control of the bend angle, allowing users to achieve accurate measurements without complex mechanical alignment procedures.
3Manufacturing precision
If calibration procedures are required for accurate bends, then measurement accuracy can be achieved, but ease of operation is reduced
Solution Approach 1:
The sensor system is pre-configured and attached to the pipe bender before use, with the processor pre-programmed to calculate bend angles from sensor data. This preliminary setup eliminates the need for on-site calibration procedures, allowing users to immediately achieve accurate bends without time-consuming calibration steps.
Solution Approach 2:
The system automatically performs all measurement and calculation functions without requiring user calibration or adjustment. The sensors continuously track the handle orientation, the processor automatically calculates the bend angle, and the display presents the results, making the entire process effortless for the user while maintaining high bend accuracy.
4Productivity
If real-time angle feedback is provided through sensors, then productivity increases, but device complexity increases
Solution Approach 1:
The patent divides the sensor system into modular components (sensors, processor, display) that attach to the existing pipe bender handle. This segmentation allows the sophisticated sensor system to be added without redesigning the entire pipe bender, maintaining productivity benefits while managing complexity through modular integration with the existing tool.
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
The system allows for more accurate and efficient bending of pipes by providing immediate and precise angle measurements, reducing user error and increasing productivity.
Implementation Method 1
A sensor, such as an accelerometer, is coupled to the handle of the pipe bender and configured to measure an orientation angle of the pipe bender
Implementation Method 2
using sensors like accelerometers and gyroscopes
Data Source
AI summary
An apparatus for determining an angle of a handle of a pipe bender includes a sensor configured to determine an orientation angle of the sensor and a display configured to display the orientation angle of the sensor. The apparatus further includes a housing configured to attach to the handle of the pipe bender. The sensor is within the housing.