Pipe Bending Apparatus with Camera-Based Shape Validation
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Solution Overview
Problem
Automotive pipe bending machines face challenges in achieving precise bends due to springback issues, which require costly and time-consuming corrective reshaping, and existing validation methods can damage fuel pipes or provide inaccurate readings.
Innovation Solution
A bending apparatus with profile validation channels and cameras that validate pipe shape without contact, ensuring precise bends by measuring dimensions before bending and assessing alignment without mechanical contact, using sensors and cameras to determine if the pipe meets specifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical position sensing devices or photo optical sensors are used to validate pipe bending accuracy, then measurement capability is provided, but the device complexity increases and potential damage to pipe surfaces occurs
Solution Approach 1:
The patent uses cameras to capture images of the pipe and creates a digital copy (image data) of the pipe's position and shape. This digital copy is then processed to determine bending accuracy, eliminating the need for complex mechanical sensing devices while maintaining measurement capability and avoiding physical contact that could damage the pipe.
Solution Approach 2:
The patent replaces mechanical position sensing devices and photo optical sensors with a camera-based imaging system. The cameras capture visual information about the pipe's position, and image processing algorithms determine bending accuracy, substituting mechanical and optical sensing mechanisms with a simpler visual inspection system.
2Measurement precision
If mechanical probes contact the pipe end for validation, then position assessment is possible, but the pipe surface quality deteriorates
Solution Approach 1:
The patent replaces mechanical contact probes with non-contact camera-based imaging systems. The cameras capture images of the pipe end and its alignment features, and image processing determines position and alignment accuracy without physical contact, thereby assessing end position while preserving pipe surface quality.
Solution Approach 2:
The patent introduces light as an intermediary between the measurement system and the pipe. Cameras capture reflected light from the pipe's alignment features and end position, transferring measurement information without mechanical contact. This intermediary approach enables position assessment while avoiding surface damage.
3Measurement precision
If pipes are moved between bending apparatus and validation jigs, then comprehensive validation is possible, but manufacturing time increases
Solution Approach 1:
The patent combines the bending apparatus and validation system into a single integrated setup. Cameras are positioned to capture pipe images at the bending location, and image processing validates the bent shape in place. This merging eliminates the need to move pipes between separate bending and validation equipment, reducing manufacturing cycle time while maintaining validation accuracy.
Solution Approach 2:
The patent enables continuous validation during or immediately after the bending process. By using cameras to capture pipe position and shape data in real-time at the bending location, the system maintains continuous measurement capability without interruption for moving pipes to separate validation jigs, thereby reducing manufacturing cycle time.
4Measurement precision
If photo optical sensors are used to detect pipe position, then non-contact measurement is achieved, but inaccurate readings occur when pipe surfaces are too far from the light beam
Solution Approach 1:
The patent uses cameras to capture complete visual images of the pipe and its alignment features from appropriate distances. The image processing system creates a digital representation of the pipe's position and orientation, providing reliable measurement data without requiring the pipe surface to be in close proximity to the sensor, thereby overcoming the limitations of photo optical sensors.
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 apparatus ensures highly precise bends without damaging the pipe and reduces manufacturing time and cost by validating the shape in real-time, preventing further corrective bending and ensuring accurate alignment.
Implementation Method 1
a camera that is perpendicular to the optical axis of the criteria pin and that is aligned to image the free end of the bent pipe and the criteria pin in two dimensions
Data Source
AI summary
An apparatus is provided for bending a pipe and checking a bent shape of the pipe. The apparatus includes a bender for forming a bend in the pipe and at least two cameras for determining an alignment of the pipe in proximity to the free end of the pipe.