Online Tube Sampling Saw System for Continuous Production
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Solution Overview
Problem
Current methods for sampling and testing tubing during production are offline and time-consuming, requiring additional personnel and causing delays between sampling and receiving test results, which hinders continuous production.
Innovation Solution
A saw system integrated with a processor, sensor, and delivery device that allows for on-line cutting and testing of tube samples, enabling real-time feedback and continuous production by cutting samples from tubing while it is still on the production line and transporting them to an inspection station.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If samples are taken offline from tubing section, then samples can be obtained for inspection, but production time is lost and additional personnel are required
Solution Approach 1:
The patent combines the sampling function with the ongoing production line by installing a saw system that cuts samples directly from the moving tubing. This merging of sampling and production operations eliminates the need for separate offline sampling, allowing both quality inspection and continuous production to occur simultaneously without stopping the production line.
Solution Approach 2:
The production line itself performs the sampling function through the integrated saw system. The tubing passes through the saw station during normal production, and samples are automatically cut and collected without requiring additional personnel to stop the line and manually take samples. The system serves itself by incorporating the inspection sampling capability into the production flow.
2Measurement precision
If samples are taken offline, then test results can be obtained, but significant time delay occurs between sampling and receiving results
Solution Approach 1:
The saw system performs preliminary sampling action directly at the production line location, cutting samples immediately when needed rather than waiting for offline sampling opportunities. This preliminary action at the source eliminates the time delay associated with transporting tubing sections to separate inspection areas, providing rapid sample acquisition for immediate testing.
Solution Approach 2:
The patent extracts the sampling operation from the offline process and integrates it directly into the production line flow. By taking out the sampling function and placing it at the production location, the system eliminates the time-consuming transport and handling steps that caused delays between sampling and testing.
3Measurement precision
If additional personnel are assigned to test formed product, then inspection can be performed, but labor costs and operational complexity increase
Solution Approach 1:
The production line is equipped with self-sampling capability through the integrated saw system, eliminating the need for additional personnel to manually collect samples. The system automatically cuts and collects samples during production, reducing dependency on extra staff for sampling operations while maintaining inspection quality.
Solution Approach 2:
The saw system serves multiple functions: it cuts samples for inspection, marks sample locations, and integrates with the production control system. This multi-functionality consolidates what would otherwise require separate personnel and equipment, reducing operational complexity while maintaining comprehensive inspection capabilities.
Data Source
AI summary
A saw and inspection system configured to allow for cutting a sample portion of a tube and inspect it without removing the tube from the production line. The sample portion of the tube may be cut with a saw and the sample portion is moved to the inspection table via a conveyer belt. This allows for a more rapid inspection of the tube without having to remove the tube from the production line, cut the sample portion and then inspect it.