Weld quality monitoring and control system for a tube mill
First Claim
1. A monitoring and control system for a tube mill capable of converting a flat metal strip to round tubing, said tube mill including a forming section which forms the flat strip into an open seam tube, a welding section for welding the edges of the seam together to form a welded tube, a sizing section for sizing the welded tube, and a cut off section for cutting the sized tube to predetermined lengths, comprising:
- a programmable logic control (PLC) for receiving electronic data transmitted from input devices, and generating signals for transmission to output devices;
means continuously measuring the width of said strip, located upstream of said forming section;
said width-measuring means being electrically connected to said PLC and including means for transmitting said width measurements as electronic data, to said PLC;
said PLC being programmed to store a set of threshold parameters for data received from said width-measuring means;
said PLC being programmed to transmit an alarm signal when the measured width received from said width-measuring means exceeds the threshold parameters programmed into said PLC;
alarm means responsive to an alarm signal from said PLC and being electrically connected to the PLC to receive electronic signals therefrom; and
a control terminal electrically connected to said PLC, including means for programming variable parameters into said PLC.
1 Assignment
0 Petitions
Accused Products
Abstract
A welded tube monitoring and control system includes a programmable logic controller (PLC) which receives data from a plurality of input apparatus which monitor the tube manufacturing process, and which generates output data to control various components of the tube manufacturing system. An apparatus for measuring the width of the flat metal strip prior to forming the tube transmits measurements to the PLC. The width of the strip is compared to a set of threshold parameters programmed in the PLC, and an alarm is triggered if the measured width exceeds these threshold parameters. A temperature measuring apparatus is located at the welding site to measure the temperature of the weld. The weld temperature is transmitted to the PLC and compared with a set of threshold parameters, and an alarm is triggered is the measured temperature exceeds the threshold parameters. An eddy-current testing apparatus is located downstream of the welding apparatus and transmits data to the PLC. The PLC compares the data from the eddy-current testing apparatus with a set of threshold parameters, and triggers an alarm if the measured data exceeds the threshold parameters. The PLC is connected to the drive for the mill, so as to shut down the manufacturing process if an alarm continues for a predetermined length of time. An override switch is provided so as to override the alarm to prevent the shut down of the mill.
39 Citations
21 Claims
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1. A monitoring and control system for a tube mill capable of converting a flat metal strip to round tubing, said tube mill including a forming section which forms the flat strip into an open seam tube, a welding section for welding the edges of the seam together to form a welded tube, a sizing section for sizing the welded tube, and a cut off section for cutting the sized tube to predetermined lengths, comprising:
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a programmable logic control (PLC) for receiving electronic data transmitted from input devices, and generating signals for transmission to output devices; means continuously measuring the width of said strip, located upstream of said forming section; said width-measuring means being electrically connected to said PLC and including means for transmitting said width measurements as electronic data, to said PLC; said PLC being programmed to store a set of threshold parameters for data received from said width-measuring means; said PLC being programmed to transmit an alarm signal when the measured width received from said width-measuring means exceeds the threshold parameters programmed into said PLC; alarm means responsive to an alarm signal from said PLC and being electrically connected to the PLC to receive electronic signals therefrom; and a control terminal electrically connected to said PLC, including means for programming variable parameters into said PLC. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A monitoring and control system for a tube mill capable of converting a flat metal strip to round tubing, said tube mill including a forming section which forms the flat strip into an open seam tube, a welding section including welding apparatus with means for welding the edges of the seam together at a weld site to form a welded tube, a sizing section for sizing the welded tube, and a cut off section for cutting the sized tube to predetermined lengths, comprising:
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a programmable logic control (PLC) for receiving electronic data transmitted from input devices, and generating signals for transmission to output devices; means for continuously measuring the width of said strip, electrically connected to said PLC and located upstream of said forming section; said width measuring means including means for transmitting said measurements as electronic data to said PLC; means for continuously measuring the temperature of said weld at the weld site, electrically connected to said PLC; said temperature measuring means including means for transmitting said measurements as electronic data to said PLC; said PLC being programmed to store a first set of threshold parameters for data received from said width measuring means, and a second set of threshold parameters for data received from said temperature measuring means; said PLC being programmed to transmit a first alarm signal to an alarm means, when the measured width received from said width measuring means exceeds the first set of threshold parameters; said PLC being programmed to transmit a second alarm signal to said alarm means, when the measured temperature received from the temperature measuring means exceeds the second set of threshold parameters; said alarm means responsive to said first and second alarm signals, electrically connected to the PLC; and a control terminal electrically connected to said PLC, including means for programming variable parameters into said PLC. - View Dependent Claims (13, 14, 15, 16, 17)
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18. A method for continuously monitoring the weld quality of an electric resistance welded tube during the manufacture thereof, the manufacture of the welded tube including the steps of forming a flat metal strip into an open seam tube, welding the edges of the open seam together at a weld site to form a welded tube, sizing the welded tube, and cutting the sized welded tube to predetermined lengths, comprising the steps of:
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providing a programmable logic control (PLC) for receiving electronic data and generating signals in response to the received electronic data; continuously measuring the width of said strip prior to the forming step; transmitting the width measurements to the PLC; said PLC comparing the transmitted width measurements with a set of programmed threshold width parameters; continuously measuring the temperature of the weld at the weld site; transmitting the temperature measurements to the PLC; said PLC comparing the transmitted temperature measurements with a set of programmed threshold temperature parameters; said PLC transmitting an alarm signal to an alarm when the width measurements exceed the width parameters; said PLC transmitting an alarm signal to said alarm when the measured temperature exceeds the threshold temperature parameters; activating said alarm in response to a transmitted alarm signal.
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19. A monitoring and control system for a tube mill capable of converting a flat metal strip to round tubing, said tube mill including a forming section which forms the flat strip into an open seam tube, a welding section for welding the edges of the seam together to form a welded tube, a sizing section for sizing the welded tube, and a cut off section for cutting the sized tube to predetermined lengths, comprising:
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a programmable logic control (PLC) for receiving electronic data transmitted from input devices, and generating signals for transmission to output devices; said welding section including welding apparatus with means for welding the edges of the open seam tube together at a weld site; means for continuously measuring the temperature of the weld at the weld site; said temperature measuring means being electrically connected to the PLC and including means for transmitting said temperature measurement as electronic data, to said PLC; said PLC being programmed to store a set of threshold parameters for data received from said temperature measuring means; said PLC being programmed to transmit an alarm signal when the measured temperature received from said temperature measuring means exceeds the threshold parameters programmed into said PLC; alarm means responsive to an alarm signal from said PLC and being electrically connected to the PLC to receive electronic signals therefrom; a control terminal electrically connected to said PLC, including means for programming variable parameters into said PLC; means for tracking the position of said strip moving through said tube mill, electrically connected to said PLC; said tracking means including means for transmitting electronic positional data to said PLC; said PLC programmed to associate said positional data with the occurrence of an alarm signal, and to generate a tracking signal identifying the location on the strip which triggered the alarm signal; said mill cut off section being electrically connected to said PLC and selectively operable in response to a "cut" signal from said PLC; and said PLC being programmed to transmit a "cut" signal to said mill cut off section in response to the generation of said tracking signal. - View Dependent Claims (20)
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21. A monitoring and control system for a tube mill capable of converting a flat metal strip to round tubing, said tube mill including a forming section which forms the flat strip into an open seam tube, a welding section for welding the edges of the seam together to form a welded tube, a sizing section for sizing the welded tube, and a cut off section for cutting the sized tube to predetermined lengths, comprising:
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a programmable logic control (PLC) for receiving electronic data transmitted from input devices, and generating signals for transmission to output devices; said welding section including welding apparatus with means for welding the edges of the open seam tube together at a weld site; means for continuously measuring the temperature of the weld at the weld site; said temperature measuring means being electrically connected to the PLC and including means for transmitting said temperature measurement as electronic data, to said PLC; said PLC being programmed to store a set of threshold parameters for data received from said temperature measuring means; said PLC being programmed to transmit an alarm signal when the measured temperature received from said temperature measuring means exceeds the threshold parameters programmed into said PLC; alarm means responsive to an alarm signal from said PLC and being electrically connected to the PLC to receive electronic signals therefrom; a control terminal electrically connected to said PLC, including means for programming variable parameters into said PLC; means for tracking the position of said strip moving through said tube mill, electrically connected to said PLC; said tracking means including means for transmitting electronic positional data to said PLC; said PLC programmed to associate said position data with the occurrence of an alarm signal, and to generate a tracking signal identifying the location on the strip which triggered the alarm signal; a dump table section downstream of said mill cut off section, said dump table section including means for receiving and storing cut off tubes; said means for receiving and storing cut off tubes including; a first storage rack for storing "acceptable" cut off tubes; a second storage rack for storing "unacceptable" cut off tubes; and sorting means for directing cut off tubes to said first and second racks; said sorting means electrically connected to said PLC and operable between a first position directing tubes to the first rack, and a second position directing tubes to the second rack; said sorting means responsive to a "dump" signal from the PLC to operate the sorting means to the second position; and said PLC programmed to transmit a "dump" signal to said sorting means in response to the generation of said tracking signal.
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Specification