Polymeric Tube Forming Apparatus with Multi-Dimensional Control
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Solution Overview
Problem
Existing tube forming apparatuses face challenges in accurately controlling polymeric tube wall thickness and concentricity, requiring manual adjustments that are time-consuming and result in material waste, with previous automation attempts leading to complex and maintenance-intensive systems.
Innovation Solution
A tube forming apparatus with a core tube adjustment system that includes axial and angular displacement devices, controlled by a computer processor and sensor system, allowing for automatic modulation of wall thickness and concentricity during operation, using servo motors and sensors to ensure precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual positioning of the die bushing is used to adjust wall thickness and concentricity, then the tube dimensions can be controlled, but the adjustment process is time-consuming and results in material waste
Solution Approach 1:
The patent replaces manual mechanical adjustment of the die bushing with an automated computer-controlled positioning system. The computer processor receives sensor signals and automatically adjusts the die bushing position, eliminating manual intervention and continuous production interruptions associated with manual adjustment.
Solution Approach 2:
The patent implements a feedback control system where sensors continuously monitor tube wall thickness and concentricity, send signals to the computer processor, which then adjusts the die bushing position accordingly. This closed-loop feedback enables real-time automatic adjustment without manual intervention.
2Productivity
If automated adjustment systems are implemented, then adjustment speed improves, but system complexity and maintenance requirements increase
Solution Approach 1:
The patent uses a universal computer processor that performs multiple functions: receiving sensor signals, processing data, controlling the die bushing position, and monitoring tube dimensions. This multi-functional approach consolidates control functions into a single system rather than requiring separate specialized devices for each function.
Solution Approach 2:
The patent merges the control functions into an integrated system where the computer processor combines signal reception, data processing, and actuator control in one unified system. The sensor system, computer processor, and die bushing positioning mechanism work as an integrated unit rather than separate components.
3Manufacturing precision
If manual adjustment of the die opening is performed, then wall thickness can be modified, but production material is wasted due to iterative adjustments
Solution Approach 1:
The patent performs preliminary setup by programming the computer with target wall thickness specifications and initial die bushing positions. The system then automatically executes adjustments based on sensor feedback, eliminating the need for iterative manual adjustments that cause material waste during the tuning process.
Solution Approach 2:
The feedback control system continuously monitors actual wall thickness and automatically adjusts the die bushing position to achieve target dimensions. This eliminates the iterative adjustment process where material is wasted during manual trial-and-error modifications.
4Measurement precision
If additional automation components are added, then control precision improves, but space requirements and maintenance needs increase
Solution Approach 1:
The patent employs a universal computer processor that handles multiple control functions including receiving sensor data, processing measurements, determining adjustment requirements, and controlling the die bushing position. This multi-functional design reduces the need for separate specialized components for each control function.
Solution Approach 2:
The system is designed to be self-regulating through automated feedback control. The computer processor automatically monitors tube dimensions via sensors and adjusts the die bushing position without external intervention, reducing the need for additional manual control components and simplifying operation.
Data Source
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AI summary
A tube forming apparatus (10) for multi-dimensional controlled forming of polymeric tube includes a housing (12) that extends around a longitudinal axis (L) and between a rear end (12A) and a discharge end (12B) thereof. The housing (12) has an inside surface (12F) that extends between the rear end (12A) and the discharge end (12B). The inside surface (12F) forms an interior area (12C) inside the housing (12). The tube forming apparatus includes a core tube assembly (14) that includes an exterior core tube (14A) and an inner core tube (14B) positioned partially therein. The tube forming apparatus includes a die (18) that has an inner die-surface (18F). A diverter tip (16) is mounted in and extends from the first inner tube end (14G) into the die (18) such that a die opening (G1) is formed between the inner die-surface (18F) and the exterior tip-surface (16F). The tube forming apparatus includes a core tube adjustment system (30) mounted proximate the rear end (12A) of the housing. The core tube adjustment (30) system includes one or both of an axial displacement device (40) configured to axially position the core tube assembly (14) for modulating wall thickness of the tube (20) and an angular displacement device (50) configured to modulate the inner core tube (14B), relative to the longitudinal axis (L), for modulating concentricity of the tube (20).