Battery Roll Groover Automation for Precise Pipe Groove Forming
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Solution Overview
Problem
Current roll groovers require skilled operators and are time-consuming, as they rely on manual operation using a crank mechanism to produce grooves on pipes, which limits efficiency and accessibility in industries like water and steam piping.
Innovation Solution
An automated roll groover system equipped with motors and an electronic processor that controls the groove roll's movement radially and circumferentially, allowing for precise groove depth adjustment and production, featuring sensors and LiDAR for safety and object detection, and a battery-powered design for portability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual crank mechanism is used to rotate the roll groover, then the device can be operated with simple mechanical components, but the operation time is excessive and requires skilled users
Solution Approach 1:
The patent replaces the manual crank mechanism with an automated motor-driven system. A motor is coupled to the groove roll through a transmission mechanism (such as a belt drive or gear system) to automatically rotate the groove roll around the pipe, eliminating the need for manual cranking and significantly reducing operation time while maintaining mechanical simplicity where possible.
Solution Approach 2:
The automated motor-driven system performs the grooving operation autonomously once positioned on the pipe. The motor self-regulates the rotation and grooving process without requiring continuous manual intervention, allowing unskilled users to operate the device easily while maintaining consistent groove quality.
2Ease of operation
If automated motors are used to drive the groove roll, then the operation time is reduced and ease of operation is improved, but the device complexity and power requirements increase
Solution Approach 1:
The patent substitutes manual mechanical operation with an automated motor system that simplifies user interaction. The motor is controlled through simple interface elements (such as a trigger or button) that require minimal training, while the complex motor control logic is encapsulated within the device's electronic processor, separating operational simplicity from control system complexity.
Solution Approach 2:
The motor-driven system integrates multiple functions: positioning the groove roll, rotating it around the pipe, controlling groove depth, and monitoring operation status. This multi-functionality is achieved through a single automated system that replaces multiple manual operations, reducing the skill level required while managing complexity through integrated control.
3Manufacturing precision
If precise groove depth control is implemented through motor adjustment, then the manufacturing precision is improved, but the device complexity increases
Solution Approach 1:
The patent implements feedback control where sensors (such as encoders or position sensors) monitor the groove roll position and depth, and this information is fed back to the electronic processor. The processor adjusts motor operation in real-time to maintain precise groove depth control, achieving high manufacturing precision through closed-loop control rather than complex mechanical adjustment mechanisms.
Solution Approach 2:
The system uses dynamic control of the motor to adjust groove depth during operation. The electronic processor can modify motor speed, torque, and position in real-time based on operational conditions, allowing precise groove formation without requiring complex pre-adjusted mechanical mechanisms. The system adapts dynamically to maintain precision.
Data Source
AI summary
Battery pack powered roll groover described herein includes a housing, an inner roller provided on the housing and configured to be received in an inner circumference of a workpiece, a groove roll provided on the housing and configured to produce a groove on the workpiece, one or more motors provided within the housing and configured to drive the groove roll, and an electronic processor electrically connected to the one or more motors. The electronic processor is configured to operate the one or more motors to perform a first operation of moving the groove roll in a radial direction, and operate the one or more motors to perform a second operation of moving the groove roll around a track in a circumferential direction. The first operation is performed to adjust a groove depth on the workpiece. The second operation is performed to produce the groove on the workpiece.