Tube Bending Mandrel Fault Detection via Force Monitoring

Solution Overview

Problem

Existing tube bending machines face challenges in detecting mandrel fragments within tubing due to the harsh environment, leading to reduced productivity and high maintenance costs, as traditional camera systems are not robust or reliable enough.

Innovation Solution

A force monitoring system using a sensor, such as a strain transducer, to detect the pulling force required to move the mandrel during the bending process, allowing for real-time detection of potential faults like broken or insufficiently lubricated mandrel pieces, and providing alerts for corrective actions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a camera system is used to detect mandrel fragments, then detection capability is provided, but machine productivity is reduced and maintenance costs increase due to the harsh environment

Engineering Contradiction:

Improvedetection reliabilityVSAvoidmachine productivity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the optical camera system with a force-based sensing system. Instead of using light and vision to detect mandrel fragments, the system uses force sensors to measure the pulling force required to retract the mandrel. This mechanical substitution eliminates the need for cameras in harsh environments, thereby maintaining detection reliability while avoiding productivity loss and high maintenance costs associated with camera systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If a camera system is used to detect mandrel fragments, then detection capability is provided, but maintenance costs increase due to the harsh and dirty environment

Engineering Contradiction:

Improvedetection reliabilityVSAvoidmaintenance costs

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

The patent replaces the optical camera system with a force-based sensing system. Instead of using light and vision to detect mandrel fragments, the system uses force sensors to measure the pulling force required to retract the mandrel. This mechanical substitution eliminates the need for cameras in harsh environments, thereby maintaining detection reliability while avoiding productivity loss and high maintenance costs associated with camera systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If traditional detection systems are used in harsh environments, then detection is attempted, but the systems are not robust or reliable enough

Engineering Contradiction:

Improveenvironmental adaptabilityVSAvoidsystem reliability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent replaces the optical camera system with a force-based sensing system. Instead of using light and vision to detect mandrel fragments, the system uses force sensors to measure the pulling force required to retract the mandrel. This mechanical substitution eliminates the need for cameras in harsh environments, thereby maintaining detection reliability while avoiding productivity loss and high maintenance costs associated with camera systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

The system effectively prevents mandrel fragments from entering the exhaust system by identifying abnormal forces, reducing downtime and maintenance costs, and ensuring higher quality tube bending processes.

Implementation Method 1

A force monitoring system using a sensor, such as a strain transducer, to detect the pulling force required to move the mandrel during the bending process

Methodology Applied

Scientific EffectForce detection: Force

Data Source

PatentUS7765841B2Quality analysis of tube bending processes including mandrel fault detection

Publication Date: 2010.08.03 OES

AI summary

A disclosed device and method are useful for monitoring a tube bending process. An example sensor detects a force associated with moving a mandrel in tubing during at least a portion of a tube bending process. The detected force is used to determine a quality of the tube bending process. For example, a detected pulling force provides an indication of whether a bent portion of a tube is within an acceptable range of a desired configuration. The detected pulling force is also useful to provide an indication of whether a condition of a mandrel or a machine used during the process is as expected.