Pipe Threading Control Using Motor Current End Detection

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Solution Overview

Problem

Conventional hand-held power drives for pipe threading require operators to manually monitor the end of the pipe, leading to uncertainty and potential loss of control, especially for less skilled users, due to difficulty in seeing the end of the pipe during rotation and the risk of torque transmission without warning.

Innovation Solution

A method utilizing a tool with an electric motor, sensor for measuring electrical current, and a controller to track motor rotations, providing an end-of-thread alert when predetermined thresholds are met, ensuring accurate thread completion and preventing uncontrollable rotation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of information

If manual monitoring of pipe end is used during threading, then operator can see the pipe end position, but operator safety deteriorates due to risk of torque transmission without warning

Engineering Contradiction:

Improvevisibility of pipe end positionVSAvoidtorque transmission risk to operator

Core Design Contradiction:

Loss of informationVSObject-affected harmful factors

Solution Approach 1:

The system continuously monitors motor current draw and compares it against predetermined thresholds to detect threading completion. When the current indicates the die has reached the pipe end, the system provides automatic feedback through alerts and automatic shutdown, eliminating the need for manual visual monitoring and preventing torque transmission to the operator.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The threading system monitors its own operational parameters (motor current) and automatically determines when threading is complete. The system serves itself by detecting completion conditions and initiating shutdown sequences without external intervention, thereby protecting the operator from torque transmission while maintaining visibility of the process.

Inventive Principle:

Principle #25Self-service

2Manufacturing precision

If automatic current-based control is implemented, then threading precision improves through automated monitoring, but device complexity increases due to additional sensors and control logic

Engineering Contradiction:

Improvethreading completion accuracyVSAvoidcontrol system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system replaces manual visual inspection and mechanical monitoring with electrical current-based detection. By substituting the mechanical/visual monitoring method with an electrical sensing system, the patent achieves more precise and consistent threading completion detection while the added complexity is confined to the electrical control domain rather than mechanical components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Stability of the object's composition

If predetermined current thresholds are used for automation, then threading consistency improves across different operators, but adaptability decreases for non-standard pipe conditions

Engineering Contradiction:

Improvethreading operation consistencyVSAvoidadaptability to non-standard pipe conditions

Core Design Contradiction:

Stability of the object's compositionVSAdaptability or versatility

Solution Approach 1:

The control system employs dynamic threshold adjustment capability, allowing the predetermined current thresholds to be modified based on specific pipe characteristics, diameter, material, and threading conditions. This enables the system to maintain consistency for standard operations while adapting to non-standard conditions when needed.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS11597022B2Algorithms and methods for controlling threading of pipe

Publication Date: 2023.03.07 EMERSON PROFESSIONAL TOOLS LLC

AI summary

Various methods are described for forming threads in a workpiece, and particularly for controlling and/or monitoring threading of workpieces. Also described are tools and a system used in performing the methods.