Welded Tube Forming with Optical Shape Feedback Before Welding
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Solution Overview
Problem
Existing welded pipe manufacturing techniques cannot confirm the shape of a metal plate during forming, allowing only detection of butt joint shifts 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 and capture light on the inner surface of the bent metal plate, allowing for real-time shape inspection and adjustment assistance to ensure accurate bending and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional welding inspection methods are used, then the detection of butting portion shift after welding is possible, but the shape confirmation of metal plate during forming is impossible
Solution Approach 1:
The patent applies preliminary action by performing shape inspection of the metal plate during the forming process itself, before welding occurs. The inspection device captures images of the metal plate shape at multiple positions along the forming line, allowing detection and correction of shape deviations before they propagate to the welding stage. This proactive inspection prevents the loss of shape information that would otherwise only be detectable after welding.
Solution Approach 2:
The patent implements feedback by using the inspection device to continuously monitor the metal plate shape during forming and providing this information back to the control system. The control system uses this feedback to adjust forming parameters in real-time, ensuring the metal plate achieves the correct shape before welding. This closed-loop feedback mechanism eliminates the information gap between forming and welding inspection.
2Manufacturing precision
If post-welding inspection only is performed, then the butting portion shift can be detected, but the manufacturing accuracy cannot be improved
Solution Approach 1:
The patent performs shape inspection during the forming process itself, allowing detection and correction of shape deviations before welding occurs. By identifying and correcting issues in the forming stage rather than after welding, the system prevents defective welded pipes from being produced in the first place, thereby improving manufacturing precision without time loss.
Solution Approach 2:
The patent eliminates the need to proceed through defective forming processes to reach welding inspection. By implementing continuous monitoring during forming, the system can immediately detect and correct deviations, skipping the time-consuming cycle of producing defective parts and then inspecting them after welding. This real-time detection prevents the loss of correction time.
3Reliability
If no real-time monitoring is implemented, then the manufacturing process is simpler, but the quality control is insufficient
Solution Approach 1:
The patent replaces complex manual inspection methods with an automated optical inspection system using image capture devices. This substitution maintains product quality reliability by providing objective, consistent shape measurement while managing device complexity through the use of standard imaging technology rather than elaborate mechanical measurement systems.
Solution Approach 2:
The inspection device is integrated into the existing forming line, allowing the system to self-monitor its own output without requiring separate external inspection equipment. The forming line essentially inspects itself by capturing images of the metal plate at various stages, improving quality reliability while minimizing additional device complexity.
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 shape monitoring and adjustment during the manufacturing process, reducing defects and improving the quality of the final product.
Implementation Method 1
a light emitter 102 and an image capturing unit 103, a welded pipe manufacturing apparatus (100) in which the light emitter (102) emits light having directivity to an inner surface of the bent metal plate (110) and the image capturing unit (103) captures the light emitted from the light emitter (102) and reflected by the metal plate (110)
Data Source
Figure 1
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Figure 2B
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.