Patent ID: 12233450

DETAILED DESCRIPTION OF THE INVENTION

Referring to the enclosed figures, it is shown an apparatus1for controlling a process for curving big size elongated pieces P, such as beams, section bars, tubes, other semi-finished elements to be curved, that can be used in the manufacturing of major engineering and construction structures, such as stadiums, bridges, airports, etcetera. The present apparatus1is adapted in particular to be assembled on a roller curving machine M, for example of the three- or four-roller type.

In the exemplary and non-limiting case shown in the figures, the curving machine M is of the three-roller type (indicated by number5), having vertical rotation axis.

The curving machine M is provided with rolling elements10, for example oblong stand rollers10, supported by slides11with adjustable position, and arranged to support the piece P in the outer area adjacent to curving rollers5, in other words upstream and downstream of rollers5with respect to the advancement of the piece P.

The apparatus1comprises a digital system that includes a control console C that is provided inside with a programmable processing unit U and provided with a high-resolution screen S (or also several screens S), for viewing data, which is operatively coupled to a high-resolution graphic card, provided with its own CPU.

In particular, the control console C can be composed of a computing apparatus, such as a personal computer, operating with a desired operative system, such as for example a Windows operative system.

The screen S can be composed of the screen already provided in the curving machine M, or there can be one or more additional screens.

The apparatus1comprises a camera unit2, operatively connected to the aforesaid processing unit U, and configured and positioned for acquiring images in real time of the elongated piece P to be curved by means of the aforesaid roller curving machine M.

The aforesaid images, which will be discussed later, can be frames obtained by a video acquisition by the camera unit2, or photos acquired directly and in sequence by the camera unit2.

In particular, the camera unit2is a 2D high definition CCD (Charge Coupled Device). In particular, the focusing of the camera unit2is of the fixed type, in order to provide images ensuring a low optical deformation.

In particular the camera unit2is of the black-and-white type such as to guarantee a higher definition.

The camera unit2is placed at a higher height than a horizontal work plane on which the elongated piece P to be curved lies and advances. Precisely, the camera unit2is supported by a horizontal arm3which is in turn coupled to a vertical upright4which can be fixed to a base or frame of the roller curving machine M. The horizontal arm3and the vertical upright4are configured to make possible an adjustment of the vertical position as regards the height of the camera unit2, which for example can be varied from about 3 metres to about 10 metres over the horizontal plane on which the piece P being processed lies.

The camera unit2is oriented according to an optical direction D for the image-acquisition that is substantially orthogonal to the horizontal work plane, that is parallel to the rotation axis of rollers5of the curving machine M.

The precise operating position O of the camera unit2, within which image acquisition must occur, is mechanically adjusted, or by means of electronic driving with a preestablished calibration procedure that enables precise measurements, correcting resolution errors. The calibration procedure is made possible by means of aim members and references cautiously positioned on the curving machine M.

The support arm3is rotatably connected to the vertical upright4in order to makes possible to move the camera unit2from the operating position O, wherein it aims at the working area, to a distancing position X wherein it eases the operations of loading and removing the elongated piece P on/from the roller curving machine M.

It is provided an electric motor40that is controlled by the control console C and provides to rotate the support arm3from the operating position O to the distancing position X and vice versa.

In an alternative variant, the camera unit2is supported in a fixed and non-rotating position.

The apparatus1comprises one or more position sensors6arranged to detect the angular position of the support arm3with respect to the vertical upright4and to control with precision the correct reaching of the operating position O and the distancing position X.

The support arm3and the vertical upright4are arranged such that a centreline plane PMof the camera unit2coincides with a vertical plane of symmetry of rollers5, in the operating position O. In this way, the acquired images are centred on the main work zone of the curving machine M.

The control console C is supported by a further support arm7that extends until a control front area intended for an operator33. The further support arm7is also mobile to make possible the loading/removing operations of the elongated piece P on/from the curving machine.

The control console C comprises a graphic interface of tactile type, a physical keyboard50, an aiming device60, such as a “mouse” and/or “touchpad” element, and possibly also a light pen, that can be useful for example to select—by means of direct contact on the viewing screen S—determined points of the image.

The digital system enables the input (schematically represented by block32inFIG.13), by the control console C, and storage into a specific memory30, of the processing unit U, of the profile of at least a virtual template T of curvature. The digital system is configured to reproduce on the screen S the real images I of the elongated piece P, detected by the camera unit2, and processed by a software31integrated in the apparatus1.

The profile of the virtual template T of curvature is directly created by the control console C. It is also possible to load a previously created file of the virtual template T of curvature by a graphic software of the CAD/CAM/CAE type. The previously created file can be imported and stored in the memory30from which it is called up by the digital system software to be reproduced on the viewing screen S.

The processing unit U is programmed to graphically reproduce the profile of the virtual template T (or of templates) superimposed to the real image I of the piece P to enable the operator33to visually compare the shape of the piece P being processed with the virtual template T superimposed on the screen.

If desired, it is possible to load/generate and reproduce on the screen S more virtual templates T, corresponding to profiles of partial curvature, i.e. more emphasized until they coincide with the desired final theoretical shape. The usefulness of such operative mode can be in particular appreciated in case in which rather complicated curvature configurations must be obtained, such as highly emphasized curvatures (reduced radii of curvature) and multiple-radius curvatures, with high radii variety. In this case, it is possible to compare, at intermediated steps of the process, the piece P being processed from time to time with a corresponding partial virtual template T, corresponding to a profile of partial curvature.

As shown in the simplified flowchart ofFIG.13, based on the visual comparison made possible by the digital system, that is easy and quick to use, the operator33can intervene giving suitable commands to the curving machine M, thus checking step by step various process parameters (speed, load applied, etcetera) adapting them to the current state of the piece being processed. The task of the operator33, who can take advantage of the precious information supplied by the digital system of the present apparatus1, is just to drive the roller curving machine M to adapt the curvature and the geometric configuration of the elongated piece P to the theoretical profile of the virtual template T of curvature.

As previously mentioned, the digital system of the control apparatus1according to the present invention is configured as an “augmented reality” control system, i.e. a system able to provide the operator33with information in addition to the mere visual perception of the image of the piece P being processed: substantially, the further graphic element composed by the virtual template T superimposed to the viewed image of the piece P is added to the real image I of the piece P (frame, or photograph obtained by the camera unit2) reproduced on the viewing screen S, thus enriching the set of data/information made available to the operator33.

The overall visual information given by the real image of the piece P matched with the artificial graphic information provided by the virtual template T ease significantly the operator33task in verifying the correct development of the curving process.

Unlike the automatic systems of the state of the art wherein the operator does not intervene during the working cycle (whose use for the present applications herein discussed is not feasible due to the above seen reasons), in the present case he takes advantage of useful graphic information provided by the control apparatus1to suitably drive the curving machine M, succeeding in avoiding working imprecisions and most of all irreparable distortions of the profile of the transverse section of the piece P.

Thanks to the optical digital system according to the present invention, the virtual template T plays the role of clear reference graphic element, in relation to which the operator33can constantly, in real time, compare the piece P being progressively curved.

Obviously, the virtual template T represents a tool that can be used immediately, intuitive and very easy to use, by all curving machine operators.

In function, the operator33manually controls the machine M, submitting the piece P to several runs (according to alternate advancing directions) through the machine rollers, such as to progressively curve the piece P. The profile of the real piece P, viewed on the screen S, as a result of the subsequent runs in the machine M, adapts progressively approaching to the desired final shape (piece PF) represented by the virtual template T.FIGS.9to11show by way of example the progressive curvature of the piece P from its initial rectilinear configuration to the final shape (piece PF).

In order to verify step by step the geometry of the piece P being processed, the operator33can, acting on the console C, translate, rotate, enlarge a part of the virtual template T superimposing it to a preestablished area of the real image I of the piece P. In particular, the operator33can superimpose one (or more) virtual template T both on the inner outline of the piece P (to measure the inner radius of curvature) and the outer outline of the piece P (to measure the outer radius of curvature).

The software, included in the digital system of the apparatus1according to the invention, makes available to the operator33a wide range of graphic tools to progressively verify the curvature of the piece P being processed, and to measure different geometric magnitudes such as radius of curvature, arc, arrow, rope etcetera.

Some functions made available by the apparatus1software are hereinafter reported for exemplary purposes.

The operator33can move the virtual template T viewed on the screen, to superimpose it on a desired zone of the image I that reproduces a determined portion of the concerned piece P. In addition to this dragging function fT, also a rotation function fRof the virtual template T, and also a zoom function fZare available to select and enlarge a determined area of the image I to enable a more accurate and restricted analysis on the portion concerned of the piece P.

InFIG.19they are schematized the piece P, in a working intermediate step, and the virtual template T, that can be dragged, on the screen S, until it superimposes on the piece P which appears on the real image I.

FIG.20shows by way of example the piece P in another possible working intermediate step: the virtual template T can be rotated, in addition to dragging, to be superimposed on the piece P and check curvature in the various zones. In this example case, superimposing the template T on the piece P highlights a correct curvature condition in the left portion Y, however it suggests the operator33that the portion on the right W still needs one or more curvature interventions.

Thanks to the “zoom” function fZ, the operator33can select and enlarge a determined area of the image I of the piece P to locally verify its geometric shape.

This function and operative possibility are shown inFIG.18, where it is shown an enlarged view of a portion of the piece P that locally has a radius of curvature Rp, not yet equal, in particular still greater than the local radius RTof the reference virtual template T.

The digital system of the control apparatus1makes also available to the operator33the possibility to superimpose the virtual template T along the centreline of the piece P. In this case the piece P can be curved aiming at matching its curvature centreline or median line to the desired profile of average curvature.

Such a possibility was not conceivable until now with the present apparatuses and with the manual-type verification systems with physical templates, due to the impossibility to have reference points where the physical template can be laid.

For greater ease ad efficiency in graphical viewing, the operator33can assign certain colours to the virtual template T, or he can highlight zones of the image I, according to his own preferences.

It is possible to measure the radius or diameter of curvature by simply “clicking” with the mouse (moving the cursor20) on three (or more) points on the profile of the piece being processed that is reproduced on the screen S thanks to the camera unit2acquisition.

The measurement of the arrow simply occurs by “clicking” on the points of the profile concerned, and the measurement of the arc occurs similarly.

All the aforesaid verification and checking operations can be easily performed by the operator33at his workstation near the comfortable ergonomic control console C, with no need to continuously move around the machine M or having to resort to one or more assistants for measuring and checking operations.

The digital system of the apparatus1also enables to measure the overall length of the piece P.

The measurement of the overall length of the profile occurs processing a plurality of photos acquired in sequence, which, after being mutually reassembled by the software31integrated in the control apparatus1, lead to reproduce the definitive geometric shape of the whole curved piece P.

According to a possible variant, shown with reference toFIGS.21to26, the control apparatus1is adapted to be used on a curving machine M′ of vertical type, having rollers5′ with horizontal shafts. In this case, the camera unit2′ is positioned in front of the curving machine M′.

The camera unit2′ is supported by a turret70fixable or that can be rested on the ground.

The camera unit2′ is placed at a due distance Y with respect to the vertical work plane on which the elongated piece P to be curved on the curving machine M′ lies and advances. InFIGS.24to26, different steps for bending the piece P are visible in sequence, for exemplary purpose.

The operation of the control apparatus1is in this case at all similar to what already described in the previous embodiment.

From what said and shown in the enclosed drawings, it is evident that a method and an apparatus1obtaining the objects set forth are provided.

Thanks to the invention it is possible to curve an elongated piece P in conditions of total safety for operator33, who can control the machine M and also verify in real time the curvature state of the piece P remaining directly and easily in his workstation before the control console C.

The advantages of a greater working precision and increase in safety for operators are integrated by further advantages as speeding up the curving cycle and reducing downtimes.

It is evident that the control apparatus1according to the invention can be applied to the iron and steel industry (especially in the heavy one), to carry out bridges, airports, stadiums, big containers (pressure tanks, boilers, heat exchangers, tanks in general, etcetera), components used in the wind industry, etcetera.

The control apparatus1is addressed to all the users of curving machines of any type; the presently used curving machines can be easily equipped with the control apparatus1by means of retrofit.

It must be understood that what said and shown in the enclosed drawings is only for illustration purpose of the method and general characteristics, as well as of an embodiment of the apparatus1according to the present invention.

Other modifications or variations can be made to the entire apparatus1, or parts thereof, and to the corresponding operating method, while remaining within the scope of the claims.