Automated Pipe Forming Press with Optical Contour Measurement
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Solution Overview
Problem
The complex process of forming thick-walled tubes for industrial applications, such as pipelines, is hindered by the need for extensive manual expertise and experience due to variables like sheet thickness and material properties, leading to inaccuracies and increased complexity in achieving desired contours and shapes.
Innovation Solution
A device and method utilizing a light source and receiver, preferably a laser system, integrated with internal forming tools to measure and adjust the inner contour of slotted tubes continuously, allowing for high-precision, automated forming processes that compensate for material fluctuations and inaccuracies in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If empirical values and manual experience are used for positioning and forming, then the process can be operated with simple equipment, but the manufacturing precision and reliability deteriorate due to disturbance variables like sheet thickness and material fluctuations
Solution Approach 1:
The patent replaces manual empirical positioning and forming with an automated optical measurement system. A light source projects a pattern onto the workpiece, and a camera captures the deformed pattern to automatically determine the contour, eliminating reliance on operator experience and manual measurement methods.
Solution Approach 2:
The patent implements a feedback loop where the measured contour is compared with the desired contour, and the forming process is automatically adjusted based on the deviation. This closed-loop control compensates for disturbance variables like sheet thickness variations and material fluctuations, maintaining high manufacturing precision.
2Reliability
If automated measurement systems are introduced to improve manufacturing precision, then the reliability of the forming process improves, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical measurement systems with an optical measurement system. A light source and camera combination provides reliable, non-contact measurement that is less susceptible to mechanical wear and alignment issues, improving process reliability while keeping the system relatively simple.
Solution Approach 2:
The patent creates an optical copy (image) of the workpiece contour and processes this digital representation for measurement and control. This allows the contour information to be extracted, stored, and analyzed without physically touching or complicating the forming process, improving reliability while maintaining system simplicity.
3Manufacturing precision
If multiple forming steps are used to achieve the desired contour, then the manufacturing precision improves, but the productivity decreases due to the time-consuming nature of sequential operations
Solution Approach 1:
The patent implements real-time feedback during the forming process, allowing for immediate correction of contour deviations. This enables fewer forming passes to be required compared to traditional methods, as each pass can be optimized based on actual measurements, thereby improving both precision and productivity.
Solution Approach 2:
The patent performs preliminary measurement and contour analysis before the forming operation, allowing the forming parameters to be pre-optimized. This preliminary action reduces the number of iterative forming steps needed, improving productivity while maintaining high precision.
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 approach enables precise, efficient, and reliable production of tubes with minimal deviations from the desired shape, reducing rejects and personnel costs by continuously monitoring and adjusting the forming process, ensuring consistent quality across the length of the tube.
Implementation Method 1
a light source (6), for example a superluminescent diode or a white light source, and at least one receiver are connected to at least one internal forming tool (3a) and serve to measure the inner contour of the slotted tube or tubular precursor (2)
Data Source
Figure 1a~1h
Figure 2~3
Figure 4
AI summary
The invention relates to a device for shaping flat products (1) into slit pipes or primary pipe products (2), comprising at least one internal shaping tool (3) for the at least stepwise shaping of the flat product (1) in the radial direction of the cross-section of the slit pipe or primary pipe product to be produced, and at least one external shaping tool (4) for shaping the flat product (1) from the exterior, characterised in that at least one light source (7) and at least one receiver (8) for measuring at least the internal contour of the slit pipe or primary pipe product are connected to at least one internal shaping tool (3). The invention further relates to a method for shaping flat products (1) into slit pipes or primary pipe products (2), with at least one internal shaping tool (3) for shaping the flat product (1) in the radial direction of the cross-section of the slit pipe or primary pipe product to be produced, and at least one external shaping tool (4) for shaping the flat product (1) from the exterior, characterised in that at least one light source (7) and at least one receiver (8) are connected to at least one internal shaping tool (3) and detect the local contour or shape of the shaped flat product (1) at least during the shaping process.