Pipe Coiling Machine with Automated Hermetic Sealing
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Solution Overview
Problem
Existing pipe coiling methods require manual intervention to maintain internal pressure, leading to increased machine downtime and reduced production efficiency due to the need for manual cap fitting and sealing operations.
Innovation Solution
A machine with a sealing gripper and measuring unit that hermetically seals and cuts pipes under constant internal pressure, using a combination of a fixed and movable jaw with ultrasound welding, allowing for automated coiling and packaging of pipes with predefined internal pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cap fitting and sealing operations are performed to maintain internal pressure, then pipe quality is maintained, but machine downtime increases and production efficiency decreases
Solution Approach 1:
The system uses sensors to automatically detect when a pipe section needs sealing and triggers the sealing mechanism without human intervention. The pipe itself signals when it requires the sealing operation, creating a self-service automated system that maintains quality while eliminating manual operations and associated downtime.
Solution Approach 2:
The system incorporates sensors that continuously monitor the pipe conveying process and provide feedback to the control unit. When a pipe section reaches the sealing position or when internal pressure changes indicate a need for sealing, the sensor signals the control unit to activate the sealing mechanism, ensuring timely sealing while maintaining continuous operation.
2Stress or pressure
If manual sealing operations are performed, then internal pressure is maintained, but machine downtime increases
Solution Approach 1:
The sealing mechanism is integrated into the continuous pipe conveying process, allowing sealing operations to occur without interrupting the overall production flow. The automated system performs sealing at optimal moments during continuous operation, eliminating the need to stop the machine for manual sealing while maintaining constant internal pressure.
Solution Approach 2:
The system prepares for sealing operations in advance by continuously monitoring pipe position and internal pressure through sensors. When conditions indicate an upcoming sealing requirement, the control unit pre-positiones the sealing mechanism and prepares the necessary components, ensuring that sealing can be executed immediately without interrupting production.
3Productivity
If automated sealing is implemented, then production efficiency increases, but device complexity increases
Solution Approach 1:
The sealing mechanism is designed to perform multiple functions: it can seal different types of pipe sections, maintain internal pressure, and integrate with the existing conveying system. The control unit serves multiple purposes by coordinating sealing operations, managing sensor inputs, and controlling the sealing mechanism, thereby reducing the need for separate dedicated components.
Solution Approach 2:
The control unit acts as an intermediary between the sensors and the sealing mechanism, processing sensor signals and coordinating the sealing operation. This intermediary approach allows the system to manage complexity centrally rather than through distributed complex mechanisms, simplifying the overall device architecture while maintaining automated functionality.
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 solution enables continuous, automated coiling of pipes under constant internal pressure, reducing machine downtime and enhancing production efficiency by eliminating the need for manual operations, resulting in improved pipe quality and reliability.
Implementation Method 1
The sealing gripper crushes and welds the head end of the pipe
Implementation Method 2
The movable jaw can have, formed inside it, a duct for transmission of ultrasounds, which are generated by an ultrasound generator, and the ultrasounds reach the crushed pipe for sealing
Data Source
AI summary
A machine for coiling pipes (1) in spool form, includes a structure (10) supporting a rotating reel (11), a feeder unit for feeding a pipe (1) to the reel (11) in a longitudinal direction (X-X), a device (12) for cutting the pipe (1), a measuring unit (20) for measuring the length of the pipe (1), arranged upstream of the cutting device (12), in the longitudinal direction (X-X). The machine includes a device for hermetically sealing the pipe arranged in a zone of the machine situated upstream in the direction of feeding of the pipe towards the reel of the means for fastening to the reel and upstream of the cutting device in the same direction of feeding.