Tube Movement Measurement Without Surface Marking in Pilger Mills
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Solution Overview
Problem
Current methods for measuring the linear and rotational movement of tubes in pilger mills or tube reducer machines are inaccurate and damaging, leading to scrap material and increased costs.
Innovation Solution
A system and method using electro-mechanical sensor devices to detect and measure the rotational and linear movement of tubes as they pass through the machine, allowing for precise comparison with anticipated measurements without damaging the tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual marking with scratch or scribe is used to measure tube movement, then measurement can be made during machine operation, but the tube is damaged and must be scrapped
Solution Approach 1:
The patent replaces the mechanical scratching/scribing system with an optical measurement system. Cameras capture images of the tube surface, and software algorithms analyze the tube's position and orientation to determine movement parameters. This substitution eliminates physical contact that causes damage while maintaining measurement capability during machine operation.
Solution Approach 2:
The patent creates a visual copy (image) of the tube surface features rather than physically marking the tube. By capturing images of existing surface characteristics and analyzing their positions in sequential frames, the system measures tube movement without altering the tube. This copying approach allows measurement while preserving the tube for use.
2Loss of information
If scratch marking is used to show feed rate elongation and turning angle, then measurement data is obtained, but all tubes become scrap material
Solution Approach 1:
The patent replaces the mechanical marking system that destroys the tube with a non-contact optical system. Image capture and computational analysis provide all necessary measurement data (feed rate elongation, turning angle) without removing material or creating scrap. The tube remains intact and usable after measurement.
Solution Approach 2:
The patent uses the tube's own surface features and natural appearance under machine operation to provide measurement information. By analyzing how the tube's existing surface characteristics move and change position between images, the system extracts measurement data from the tube itself without adding marks or altering it, eliminating the need to scrap the tube.
3Measurement precision
If current manual measurement method is used, then simple equipment is required, but measurement accuracy is insufficient for precise tube quality control
Solution Approach 1:
The patent replaces simple mechanical measurement tools with an optical measurement system consisting of cameras, lighting, and computational software. While the device complexity increases, the measurement precision dramatically improves, enabling accurate detection of tube movement parameters for quality control. The complexity is justified by the significant gain in measurement accuracy and elimination of tube scrap.
Data Source
AI summary
A system and method for measuring tube movement through a tube altering machine includes a first sensor device for detecting a rotational movement of the tube caused by the tube altering machine as the tube passes therethrough. A second sensor device detects a linear movement of the tube caused by the tube altering machine as the tube passes therethrough. These precise measurements are achieved without marking or damaging the tube material and can be compared to anticipated measurements to determine if machine settings should be altered.