Welded Pipe Forming with Optical Shape Inspection Before Welding
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Solution Overview
Problem
Existing welded pipe manufacturing techniques cannot confirm the shape of a metal plate during forming, only detecting shifts in the butting portion after welding, which limits the accuracy of the manufacturing process.
Innovation Solution
A welded pipe manufacturing apparatus and method that includes a bending unit, a light emitter, and an image capturing unit to emit directional light and capture the reflected light from the metal plate's inner surface, allowing for real-time shape inspection and adjustment of the bending die arrays and roller group to ensure accurate shaping and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional welding inspection methods are used, then the butting portion shift can be detected after welding, but the shape of the metal plate during forming cannot be confirmed
Solution Approach 1:
The patent applies preliminary action by performing shape inspection during the forming process itself, rather than waiting until after welding. The light emitter and image capturing unit are positioned to inspect the metal plate shape while it is being formed by the bending rollers, allowing real-time detection and correction of shape deviations before welding occurs.
Solution Approach 2:
The patent uses light as an intermediary to enable shape detection. A light emitter projects light onto the metal plate, and an image capturing unit captures the reflected light pattern, which reveals the shape of the metal plate during forming. This optical intermediary system allows non-contact measurement of the forming process.
2Manufacturing precision
If real-time shape inspection is implemented, then the manufacturing precision can be improved, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical measurement systems with an optical system. Instead of using mechanical probes or contact-based measurement devices to inspect the metal plate shape, the invention uses light emission and image capture to achieve non-contact measurement, thereby reducing mechanical complexity while maintaining measurement accuracy.
Solution Approach 2:
The patent creates an optical copy or image of the metal plate shape during forming. The image capturing unit captures light reflected from the metal plate, creating a visual representation of its shape that can be analyzed without physically touching or interfering with the forming process. This copying approach simplifies the measurement system compared to direct mechanical measurement.
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
Enables the production of more accurate welded pipes by allowing for real-time adjustments during the manufacturing process, improving the butting property and overall quality of the welded pipes.
Implementation Method 1
an image capturing unit that captures light emitted by the light emitter and reflected by the metal plate
Data Source
AI summary
To manufacture a high-quality welded pipe, there is provided a welded pipe manufacturing apparatus for manufacturing a welded pipe by bending a metal plate and welding butting end portions of the metal plate. The welded pipe manufacturing apparatus includes a bending unit that bends the metal plate, a light emitter that emits directional light to an inner surface of the metal plate bent by the bending unit, an image capturing unit that captures light emitted by the light emitter and reflected by a surface of the metal plate, and an adjustment assistance unit that assists adjustment of the bending unit in accordance with a shape of the reflected light.