Vision-Guided Wire Rod Coil Trimming for Accurate Ring Sampling
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Solution Overview
Problem
Traditional inline high speed shear machines for trimming wire rod billets are complex, costly, and require high maintenance due to their intricate control systems and high operating speeds, making them inefficient and prone to errors.
Innovation Solution
An automated trimming system utilizing a vision system and trimming robots to identify and cut the correct number of rings in a coil, with a custom hook arrangement and screw rolls to separate and position the rings for precise trimming, allowing for operator-free trimming and reduced capital and operating costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a traditional inline high speed shear is used to trim wire rod billets at 120-130 m/s, then trimming speed is improved, but device complexity and maintenance requirements increase significantly
Solution Approach 1:
The system divides the trimming operation into discrete segments: a vision system captures images of the coil, identifies ring positions and counts, and determines sheared positions; then a controller processes this data to guide the trimming mechanism. This segmentation of the trimming process into detection and execution phases reduces machine complexity while maintaining efficiency
Solution Approach 2:
The patent replaces the complex mechanical high-speed shear system with a vision-based detection system and a controlled trimming mechanism. The vision system uses cameras and image processing to identify ring positions, eliminating the need for complex mechanical sensing and control systems required by traditional high-speed shears
2Manufacturing precision
If a traditional high speed shear with complex control system is used, then trimming accuracy is improved, but operating cost and maintenance requirements increase
Solution Approach 1:
The vision system automatically detects ring positions, counts rings, and determines sheared positions without human intervention. The controller automatically processes the vision data and guides the trimming mechanism, creating a self-service system that eliminates the need for operators to manually monitor or adjust complex control systems, thereby reducing operating costs and maintenance requirements
Solution Approach 2:
The vision system provides real-time feedback on ring positions and coil characteristics to the controller, which adjusts the trimming operation accordingly. This feedback loop ensures high trimming accuracy while simplifying operation, as the system automatically compensates for variations in coil geometry and ring positioning
3Adaptability or versatility
If multiple switch pipes and guides are used per material size, then adaptability is improved, but device complexity and capital cost increase
Solution Approach 1:
The vision system serves multiple functions: it identifies ring positions, counts rings, determines sheared positions, and adapts to different material sizes and coil geometries. This single multi-functional system replaces the traditional requirement for multiple specialized components (switch pipes, guides) for different material sizes, thereby reducing device complexity while maintaining adaptability
Solution Approach 2:
The system dynamically adjusts its operation based on real-time vision data. The controller processes vision information to determine the appropriate trimming parameters for each specific coil and material size, allowing the system to adapt to different materials without requiring physical reconfiguration of multiple fixed components
Data Source
AI summary
An automated trimming system is provided that includes a vision system identifying the number of rings positioned within a coil and sheared positions where the rings need to be cut. One or more trimming mechanisms receive the sheared positions and proceed to cut the rings at the sheared positions. A hook arrangement interfaces with the coil for transferring the coil to a trimming area. Moreover, an automated trimming system is provided that includes a coil having a plurality of rings. One or more trimming mechanisms select a number of rings from the coil and proceed to form a sample of desired length, by cutting a portion of the rings. A receiver unit receives the sample from the one or more trimming mechanisms to evaluate the quality of the sample.