Metal Pipe Forming Roll Positioning for Adaptive Threading
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Solution Overview
Problem
Existing pipe mills lack a systematic method for automatically adjusting forming tool positions during initial threading and dimension changes, leading to inefficiencies and manual adjustments based on operator experience, which are inadequate for handling material individuality and lubricant interference.
Innovation Solution
A method and apparatus that utilize forming simulation analysis, three-dimensional elastoplastic deformation finite element methods, and machine/deep learning techniques to automatically adjust forming tool positions based on correlations between material dimensions and roll positions, enabling continuous operation and automatization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual adjustment of forming tool positions is performed based on operator experience, then the pipe mill can handle initial threading and dimension changes, but the process is inefficient and cannot adequately handle material individuality and lubricant interference
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated control system that uses sensors to detect material properties and lubricant conditions, then automatically adjusts forming tool positions. This substitution eliminates the inefficiencies of manual operation while maintaining the ability to handle material individuality and lubricant interference.
Solution Approach 2:
The forming tool positioning system performs self-adjustment based on real-time feedback from sensors detecting material properties and lubricant interference. The system automatically compensates for variations without requiring external manual intervention, thereby improving initial threading efficiency while adapting to material individuality.
2Device complexity
If forming tool positions are fixed for economic reasons, then the pipe mill configuration is simplified, but the mill encounters excess or deficiency of mechanical rigidity and cannot adapt to different materials and dimensions
Solution Approach 1:
The patent introduces dynamic adjustability to the forming tool positions, allowing the mill to adapt its configuration based on material properties and dimension requirements. The position adjustment mechanism enables the system to transition between different forming conditions while maintaining a relatively simple base configuration, thus balancing device complexity with adaptability.
Solution Approach 2:
The system changes the positional parameters of forming tools automatically based on detected material properties and lubricant conditions. This parameter adjustment allows the same physical equipment to handle diverse materials and dimensions without requiring multiple fixed configurations, thereby maintaining simplicity while achieving versatility.
3Adaptability or versatility
If multi-use forming rolls are used to cover wide dimension ranges, then the pipe mill can handle various pipe sizes, but the forming force distribution becomes non-optimal for different materials
Solution Approach 1:
The patent adjusts the positional parameters of multi-use forming rolls based on material properties and dimension requirements. By dynamically changing the location and spacing of forming rolls, the system optimizes forming force distribution for each specific material and dimension combination, thereby maintaining manufacturing precision across a wide dimension range.
Solution Approach 2:
The system applies different forming force distributions at different locations along the material based on local material properties and dimension requirements. The position adjustment mechanism enables localized optimization of forming forces, allowing multi-use rolls to achieve optimal performance for each specific forming condition rather than compromising uniform performance across all conditions.
4Loss of information
If conventional deformation simulation is performed to predict material behavior, then the forming process can be planned, but the individuality of the pipe mill and material causes large differences between expected and actual behavior
Solution Approach 1:
The patent implements a feedback system where sensors detect actual material properties and forming conditions during operation, and this information is used to adjust forming tool positions in real-time. This closed-loop feedback compensates for the differences between simulation predictions and actual behavior caused by mill and material individuality, thereby improving both predictability and reliability.
Solution Approach 2:
The system performs preliminary detection of material properties and lubricant conditions before the forming process begins, allowing pre-adjustment of forming tool positions based on anticipated material behavior. This preliminary action reduces the gap between simulation expectations and actual performance by accounting for material and mill individuality before forming commences.
Data Source
AI summary
In a method for manufacturing a metal pipe from a metal plate using a forming tool, the position of the tool is optimized simply and correctly by incorporating individuality of the raw material plate into setting of the tool position.As a preparatory stage, a forming process is analyzed by simulation for each plate. Based on result of the analysis, correlation between a deformed shape value of a raw pipe and tool position information is acquired. Then, the forming process for each plate is stored as correlation between the deformed shape value of the raw pipe and the tool position information. During pipe manufacturing, a deformed shape value of the raw pipe is measured actually while a plate is passed. On the basis of the actually measured deformed shape value, a forming process for the raw pipe is expected and assumed (by using the correlation). Tool position information necessary for implementing the expected and assumed forming process is retrieved from the stored correlation. The retrieved tool position information is realized at a stand array.