METHOD AND APPARATUS FOR CONTROLLING A PROCESS FOR CURVING ELONGATED PIECES AND ROLLING CURVING MACHINE

Abstract

A method for curving an elongated piece uses a digital system which includes a control console having a programmable processing unit and a screen for displaying data and a camera connected with the processing unit and configured and positioned for acquiring images of the elongated piece. In accordance with the method, the profile of at least one virtual template of curvature is stored in the processing unit and a real image of the elongated piece is detected. The profile of the virtual template and the real image of the elongated piece are reproduced and compared in real time. The roller curving machine is driven and the curvature and the geometric configuration of the elongated piece are matched with the profile of the virtual template of curvature.

Claims

1. Method for controlling a process for curving an elongated piece by a digital system including a control console provided with a programmable processing unit and with a viewing screen for displaying data, associable with a roller curving machine for curving said elongated piece, and a camera unit, operationally connected to said processing unit, and configured and positioned for acquiring images of the elongated piece to be curved by said roller curving machine; comprising the steps of storing the profile of at least one virtual template of curvature in said processing unit of the control console; detecting, by said camera unit, a real image of the elongated piece to be curved positioned on said roller curving machine; orienting said camera unit according to an optical direction for the image acquisition substantially orthogonal to a working plane on which said elongated piece to be curved lies aid advances, wherein said image is composed of a frame obtained by a video acquisition from said camera unit or of a photograph directly acquired by said camera unit; simultaneously reproducing the profile of said at least one virtual template and the real image of the elongated piece detected by said camera unit on said viewing screen for enabling an operator to graphically compare the piece being progressively curved with said virtual template serving as reference graphical element; comparing in real time the real image detected by said camera unit of said elongated piece reproduced on said viewing screen with the profile of said at least one virtual template, reproduced on said viewing screen and superimposed on said real image, driving said roller curving machine and matching the curvature and the geometric configuration of the elongated piece with the profile of the virtual template of curvature.

2. Method according to claim 1, wherein the profile of said at least one virtual template of curvature is directly created by said control console, or it is provided to import a file that was previously created by a graphic software of the CAD/CAM/CAE type and store said file in, and call up from, a memory, and wherein it is provided to acquire a plurality of images in sequence, during the curving cycle.

3. Method according to claim 1, and further comprising the step of detecting a geometric parameter of the elongated piece by a measurement by directly clicking on the real image reproduced on said screen with a cursor.

4. Method according to claim 1, and further comprising the step of reproducing a plurality of progressive virtual templates, corresponding to subsequent intermediate curvature states of the elongated piece.

5. Method according to claim 1, wherein the profile of said at least one virtual template is a curved line having a single-radius or multi-radius curvature.

6. Method according to claim 1, and further comprising the step of dragging and/or rotating a virtual template on a desired zone of the real image to superimpose a portion of said virtual template on a portion of the elongated piece and enlarge said zone of the image to check the correct curvature of said portion of piece.

7. Method according to claim 1, and further comprising the step of orienting said camera unit so that a centreline plane of said camera unit coincides, in said operating position, with a vertical plane of symmetry of said rollers of said curving machine, so that the acquired images are centred on the main work area of said curving machine.

8. Computer product incorporated into a data support included in a digital system and comprising code portions to perform the method according to claim 1 when said computer product is run by said processing unit of said digital system.

9. Apparatus for controlling a process for curving an elongated piece, suitable for being installed on a roller curving machine, and configured for implementing the method according to claim 1, comprising: a. a digital system that includes a control console provided with a programmable processing unit and with a screen for displaying data, b. a camera unit, operationally connected to said processing unit, and configured and positioned for acquiring images of the elongated piece to be curved by said roller curving machine; wherein said digital system is configured for inputting by said control console and storing in said processing unit the profile of at least one virtual template of curvature, and for reproducing on said screen a real image of said elongated piece detected by said camera unit, and wherein said processsing unit is programmed to graphically reproduce the profile of said at least one virtual template superimposed on said real image of the elongated piece to enable an operator, on the basis of a visual graphic comparison or measurement on said screen to drive said roller curving machine to match the curvature and the geometric configuration of the elongated piece with the profile of said virtual template of curvature.

10. Apparatus according to claim 9, wherein said camera unit is placed at a higher position than a horizontal work plane on which said elongated piece to be curved lies and advances, said camera unit being supported by a horizontal arm that is in turn coupled with a vertical upright that is adapted to be coupled with said curving machine having vertical rollers.

11. Apparatus according to claim 9, wherein said camera unit is placed at a distance from a vertical work plane on which said elongated piece to be curved lies and advances, said camera unit being supported by a turret that is fixable to or that can be lied on the ground, adapted to be oriented and faced towards said curving machine having horizontal rollers.

12. Apparatus according to claim 10, wherein said camera unit is oriented according to an optical direction for image-acquisition that is substantially orthogonal to said work plane and parallel to the rotation axis of the rollers of said curving machine.

13. Apparatus according to claim 10, wherein said support arm is rotatably connected to said vertical upright so as to enable the movement of said camera unit from an operating position, wherein it aims at the work area, to a distancing position in which it facilitates the operations of loading and removing the elongated piece onto/from said curving machine.

14. Apparatus according to claim 13, further comprising one or more position sensors arranged for detecting the angular position of said support arm with respect to said vertical upright and controlling with precision that said operating position and said distancing position have been correctly reached.

15. Apparatus according to claim 13 wherein said support arm and said vertical upright are arranged so that a centreline plane of said camera unit coincides, in said operating position, with a vertical plane of symmetry of said rollers, so that the acquired images are centred on the main work area of said curving machine.

16. Apparatus according to claim 9, wherein said control console is supported by a further support arm that extends as far as a front control zone intended for an operator, said further support arm being movable to enable the operations of loading/removal of the elongated piece onto/from said curving machine.

17. Apparatus according to claim 9, wherein said control console comprises a graphic interface of tactile type, a physical keyboard, an aiming device, such as a “mouse” and/or “touchpad” element, and a light pen.

18. Apparatus according to claim 9, wherein said control console comprises a computing apparatus such as a personal computer in which said processing unit is provided, said personal computer including a memory into which a computer product is incorporated.

19. Roller curving machine, comprising three or more rollers for curving an elongated piece, and provided with the apparatus for controlling a curving process according to claim 9.

20. Apparatus according to claim 11, wherein said camera unit is oriented according to an optical direction for image-acquisition that is substantially orthogonal to said work plane and parallel to the rotation axis of the rollers of said curving machine.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0051] The invention will be better understood and implemented referring to the enclosed drawings, which illustrate an exemplary and non-limiting embodiment thereof, wherein:

[0052] FIGS. 1 and 2 show the apparatus according to the invention combined to a roller curving machine;

[0053] FIGS. 3 and 4 are enlarged views of details taken from FIG. 2;

[0054] FIG. 5 is a view from above of the apparatus combined to the curving machine;

[0055] FIG. 6 is a view from above showing the apparatus in distancing position;

[0056] FIG. 7 shows the apparatus in another position;

[0057] FIG. 8 shows the apparatus in an operating position;

[0058] FIGS. 9 to 11 show the progressive operation for curving one piece;

[0059] FIGS. 12 and 13 are block diagrams relative to the work of the apparatus according to the invention;

[0060] FIGS. 14 to 16 show a control console included in the apparatus according to the invention;

[0061] FIGS. 17 and 18 schematically show a graphic interface associated to the aforesaid control console of the apparatus;

[0062] FIGS. 19 and 20 schematize a piece and a virtual template and potential operations made possible by the apparatus according to the invention.

[0063] FIG. 21 shows another embodiment of the apparatus according to the invention, adapted to be mounted on a curving machine provided with rollers having horizontal shafts;

[0064] FIG. 22 is a side view of the apparatus combined to the curving machine shown in FIG. 21;

[0065] FIG. 23 shows from the front an apparatus combined to the curving machine on which a beam to be curved is loaded;

[0066] FIGS. 24 to 26 show, in sequence, different steps of processing the beam placed on the curving machine with horizontal rollers.

DETAILED DESCRIPTION OF THE INVENTION

[0067] Referring to the enclosed figures, it is shown an apparatus 1 for 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 apparatus 1 is adapted in particular to be assembled on a roller curving machine M, for example of the three- or four-roller type.

[0068] In the exemplary and non-limiting case shown in the figures, the curving machine M is of the three-roller type (indicated by number 5), having vertical rotation axis.

[0069] The curving machine M is provided with rolling elements 10, for example oblong stand rollers 10, supported by slides 11 with adjustable position, and arranged to support the piece P in the outer area adjacent to curving rollers 5, in other words upstream and downstream of rollers 5 with respect to the advancement of the piece P.

[0070] The apparatus 1 comprises 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.

[0071] 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.

[0072] 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.

[0073] The apparatus 1 comprises a camera unit 2, 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.

[0074] The aforesaid images, which will be discussed later, can be frames obtained by a video acquisition by the camera unit 2, or photos acquired directly and in sequence by the camera unit 2.

[0075] In particular, the camera unit 2 is a 2D high definition CCD (Charge Coupled Device). In particular, the focusing of the camera unit 2 is of the fixed type, in order to provide images ensuring a low optical deformation.

[0076] In particular the camera unit 2 is of the black-and-white type such as to guarantee a higher definition.

[0077] The camera unit 2 is 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 unit 2 is supported by a horizontal arm 3 which is in turn coupled to a vertical upright 4 which can be fixed to a base or frame of the roller curving machine M. The horizontal arm 3 and the vertical upright 4 are configured to make possible an adjustment of the vertical position as regards the height of the camera unit 2, 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.

[0078] The camera unit 2 is 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 rollers 5 of the curving machine M.

[0079] The precise operating position O of the camera unit 2, 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.

[0080] The support arm 3 is rotatably connected to the vertical upright 4 in order to makes possible to move the camera unit 2 from 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.

[0081] It is provided an electric motor 40 that is controlled by the control console C and provides to rotate the support arm 3 from the operating position O to the distancing position X and vice versa.

[0082] In an alternative variant, the camera unit 2 is supported in a fixed and non-rotating position.

[0083] The apparatus 1 comprises one or more position sensors 6 arranged to detect the angular position of the support arm 3 with respect to the vertical upright 4 and to control with precision the correct reaching of the operating position O and the distancing position X.

[0084] The support arm 3 and the vertical upright 4 are arranged such that a centreline plane P.sub.M of the camera unit 2 coincides with a vertical plane of symmetry of rollers 5, in the operating position O. In this way, the acquired images are centred on the main work zone of the curving machine M.

[0085] The control console C is supported by a further support arm 7 that extends until a control front area intended for an operator 33. The further support arm 7 is also mobile to make possible the loading/removing operations of the elongated piece P on/from the curving machine.

[0086] The control console C comprises a graphic interface of tactile type, a physical keyboard 50, an aiming device 60, 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.

[0087] The digital system enables the input (schematically represented by block 32 in FIG. 13), by the control console C, and storage into a specific memory 30, 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 unit 2, and processed by a software 31 integrated in the apparatus 1.

[0088] 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 memory 30 from which it is called up by the digital system software to be reproduced on the viewing screen S.

[0089] 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 operator 33 to visually compare the shape of the piece P being processed with the virtual template T superimposed on the screen.

[0090] 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.

[0091] As shown in the simplified flowchart of FIG. 13, based on the visual comparison made possible by the digital system, that is easy and quick to use, the operator 33 can 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 operator 33, who can take advantage of the precious information supplied by the digital system of the present apparatus 1, 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.

[0092] As previously mentioned, the digital system of the control apparatus 1 according to the present invention is configured as an “augmented reality” control system, i.e. a system able to provide the operator 33 with 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 unit 2) reproduced on the viewing screen S, thus enriching the set of data/information made available to the operator 33.

[0093] 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 operator 33 task in verifying the correct development of the curving process.

[0094] 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 apparatus 1 to 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.

[0095] 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 operator 33 can constantly, in real time, compare the piece P being progressively curved.

[0096] Obviously, the virtual template T represents a tool that can be used immediately, intuitive and very easy to use, by all curving machine operators.

[0097] In function, the operator 33 manually 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 P.sub.F) represented by the virtual template T. FIGS. 9 to 11 show by way of example the progressive curvature of the piece P from its initial rectilinear configuration to the final shape (piece P.sub.F).

[0098] In order to verify step by step the geometry of the piece P being processed, the operator 33 can, 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 operator 33 can 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).

[0099] The software, included in the digital system of the apparatus 1 according to the invention, makes available to the operator 33 a 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.

[0100] Some functions made available by the apparatus 1 software are hereinafter reported for exemplary purposes.

[0101] The operator 33 can 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 f.sub.T, also a rotation function f.sub.R of the virtual template T, and also a zoom function f.sub.Z are 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.

[0102] In FIG. 19 they 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.

[0103] FIG. 20 shows 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 operator 33 that the portion on the right W still needs one or more curvature interventions.

[0104] Thanks to the “zoom” function f.sub.Z, the operator 33 can select and enlarge a determined area of the image I of the piece P to locally verify its geometric shape.

[0105] This function and operative possibility are shown in FIG. 18, where it is shown an enlarged view of a portion of the piece P that locally has a radius of curvature R.sub.p, not yet equal, in particular still greater than the local radius R.sub.T of the reference virtual template T.

[0106] Advantageously, the digital system of the control apparatus 1 makes also available to the operator 33 the 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.

[0107] 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.

[0108] For greater ease ad efficiency in graphical viewing, the operator 33 can assign certain colours to the virtual template T, or he can highlight zones of the image I, according to his own preferences.

[0109] It is possible to measure the radius or diameter of curvature by simply “clicking” with the mouse (moving the cursor 20) on three (or more) points on the profile of the piece being processed that is reproduced on the screen S thanks to the camera unit 2 acquisition.

[0110] The measurement of the arrow simply occurs by “clicking” on the points of the profile concerned, and the measurement of the arc occurs similarly.

[0111] All the aforesaid verification and checking operations can be easily performed by the operator 33 at 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.

[0112] The digital system of the apparatus 1 also enables to measure the overall length of the piece P.

[0113] 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 software 31 integrated in the control apparatus 1, lead to reproduce the definitive geometric shape of the whole curved piece P.

[0114] According to a possible variant, shown with reference to FIGS. 21 to 26, the control apparatus 1 is adapted to be used on a curving machine M′ of vertical type, having rollers 5′ with horizontal shafts. In this case, the camera unit 2′ is positioned in front of the curving machine M′.

[0115] The camera unit 2′ is supported by a turret 70 fixable or that can be rested on the ground.

[0116] The camera unit 2′ 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. In FIGS. 24 to 26, different steps for bending the piece P are visible in sequence, for exemplary purpose.

[0117] The operation of the control apparatus 1 is in this case at all similar to what already described in the previous embodiment.

[0118] From what said and shown in the enclosed drawings, it is evident that a method and an apparatus 1 obtaining the objects set forth are provided.

[0119] Thanks to the invention it is possible to curve an elongated piece P in conditions of total safety for operator 33, 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.

[0120] 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.

[0121] It is evident that the control apparatus 1 according to the invention can be advantageously 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.

[0122] The control apparatus 1 is addressed to all the users of curving machines of any type; the presently used curving machines can be easily equipped with the control apparatus 1 by means of retrofit.

[0123] 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 a preferred embodiment of the apparatus 1 according to the present invention.

[0124] Other modifications or variations can be made to the entire apparatus 1, or parts thereof, and to the corresponding operating method, while remaining within the scope of the claims.