METHOD AND APPARATUS FOR ULTRASONIC EXTRUSION CONTROL

Abstract

An ultrasonic transducer fixture has an entrance and an exit for tubular extrudate passing therethrough; ultrasonic transducers within a closed chamber in position for passage of the tubular extrudate therebetween; and a vacuum source communicating with the chamber interior for maintaining sub-atmospheric pressure within the chamber. The water level in the chamber is controlled so that the ultrasonic transducers remain immersed in the water.

Claims

1. A method for ultrasonically measuring an outer diameter of a tubular extrudate exiting an extrusion die, the improvement comprising: providing a closed chamber having inlet and exit openings for passage therethrough of the tubular extrudate; positioning a plurality of ultrasonic transducers within the chamber and spaced from the tubular extrudate; controlling a water level in the chamber sufficiently to cover the transducers; and automatic controlling and maintaining an internal pressure of the chamber at a level sufficiently below atmospheric pressure to preclude escape of water from the chamber through the inlet and exit openings as the tubular extrudate moves through the chamber.

2. The method of claim 1, further comprising monitoring the water level in the chamber relative to the transducers; introducing water into the chamber whenever the water level falls sufficiently that a top of one or more of the ultrasonic transducers is exposed; and continuing introducing water into the chamber until the water level is above the tops of the one or more ultrasonic transducers by a preselected amount.

3. The method of claim 1, further comprising: continuously monitoring the internal pressure of the chamber; and lowering or raising the internal pressure of the chamber while flooding or draining water from the chamber to maintain the internal pressure of the chamber at a level sufficiently below atmospheric pressure to preclude escape of water from the chamber through the inlet and exit openings as the tubular extrudate moves through the chamber.

5. The method of claim 1, further comprising determining the outer diameter of the tubular extrudate based on an output of the one or more ultrasonic transducers.

6. The method of claim 1, further comprising: providing a holder on which the one or more ultrasonic transducers are mounted; and determining a position of the tubular extrudate in relation to the holder based on an output of the one or more ultrasonic transducers.

7. The method of claim 6, further comprising adjusting a position of the chamber in relation to the tubular extrudate.

8. The method of claim 7, wherein adjusting a position of the chamber in relation to the tubular extrudate comprises moving the chamber so that the tubular extrudate is substantially centered within the holder.

9. The method of claim 1, further comprising mounting the chamber on a cooling-medium tank.

10. An ultrasonic transducer fixture for measuring parameters of a moving tubular extrudate, comprising: a closed chamber having an interior, and an entrance and an exit for passage of the tubular extrudate through the interior; a holder positioned within the interior of the chamber; a plurality of ultrasonic transducers mounted on the holder and positioned for passage of the tubular extrudate therebetween; a vacuum source in fluid communication with the interior of the chamber and configured to maintain an internal pressure of the chamber at a level below atmospheric pressure; a pump in fluid communication with the interior of the chamber; and a control electrically connected to the pump and configured to generate an output that, when received by the pump, causes the pump to introduce water into the interior of the chamber to maintain a water level in the interior of the chamber above the tops of the one or more ultrasonic transducers.

11. The fixture of claim 10, wherein the control is electrically connected to the vacuum source and is further configured to generate another output that, when received by the vacuum source, causes the vacuum source to maintain the internal pressure of the chamber at a level sufficiently below atmospheric pressure to preclude escape of the water from the chamber through the entrance and exit as the tubular extrudate moves through the chamber.

12. The fixture of claim 10, further comprising a first iris valve mounted at the entrance of the chamber for passage therethrough of the tubular extrudate; and a second iris valve mounted at the exit of the chamber for passage therethrough of the tubular extrudate.

13. The fixture of claim 10, wherein the holder has a bore formed therein for passage therethrough of the tubular extrudate.

14. The fixture of claim 10, wherein the ultrasonic transducers are arranged on the holder in opposed pairs.

15. The fixture of claim 10, wherein the chamber has a first substantially vertical wall having the entrance to the chamber formed therein; and a second substantially vertical wall having the exit to the chamber formed therein.

16. The fixture of claim 10, wherein the chamber is configured to be mounted on a cooling-medium tank.

17. The fixture of claim 11, further comprising a water level sensor electrically connected to the control and configured to sense the water level in the interior of the chamber.

18. An apparatus, comprising: an ultrasonic transducer fixture comprising: a vacuum chamber having an entrance for receiving a tubular extrudate from an extrusion die, and an exit; a holder within the vacuum chamber; a plurality of ultrasonic transducers mounted on the holder and positioned for passage of the tubular extrudate therebetween; and a vacuum source in fluid communication with an interior of the vacuum chamber and configured to maintain an internal pressure of the vacuum chamber at a level below atmospheric pressure; and a cooling-medium tank, wherein the ultrasonic transducer fixture is mounted on the cooing-medium tank, and the cooling-medium tank has an entrance configured to receive the tubular extrudate after the tubular extrudate exits the vacuum chamber.

19. The apparatus of claim 18, wherein the cooling-medium tank and the vacuum chamber are configured to be movable in relation to the extrusion die.

20. The apparatus of claim 19, further comprising a signal processing device communicatively coupled to the ultrasonic transducers and configured to determine an outer diameter and a relative position of the tubular extrudate based on outputs of the ultrasonic transducers.

21. The apparatus of claim 20, further comprising: one or more actuators mounted on the cooling-medium tank and configured to move the cooling-medium tank; and a controller communicatively coupled to the one or more actuators and the signal processing device, wherein the controller is configured to generate an output that, when received by the one or more actuators, causes the one or more actuators to move the cooling-medium tank and the fixture.

22. The apparatus of claim 21, wherein the output of the controller, when received by the one or more actuators, causes the one or more actuators to move the cooling-medium tank and the fixture so that the tubular extrudate becomes centered within the holder.

23. The apparatus of claim 20, further comprising a video display communicatively coupled to the signal processing device, wherein the signal processing device, in response to the outputs of the ultrasonic transducers, is further configured to generate an output that, when received by the video display, causes the video display to display an image representative of an actual position of the tubular extrudate in relation to the one or more ultrasonic transducers, and in relation to an established target defined by the centerline of an intended path of the tubular extrudate through the holder and the tank.

Description

DESCRIPTION OF THE DRAWINGS

[0039] FIG. 1 is a schematic view in side elevation of ultrasonic extrusion control apparatus in accordance with the invention.

[0040] FIG. 2 is a schematic view in side elevation of a vacuum chamber portion of the ultrasonic extrusion control apparatus illustrated schematically in FIG. 1.

[0041] FIG. 3 is a schematic view in elevation taken at arrows A-A in FIG. 2 of an ultrasonic sensor holder for use with the ultrasonic extrusion control apparatus illustrated in FIGS. 1 and 2.

[0042] FIG. 4 is a schematic view of various electrical components of the ultrasonic extrusion control apparatus illustrated in FIGS. 1 and 2.

DESCRIPTION OF THE INVENTIONS

[0043] In one of its aspects, the disclosed technology provides a water-filled and water-level controlled vacuum chamber housing ultrasonic sensors/transducers for measuring the diameter of a tubular extrudate. The housing is independent of the tank containing the cooling medium for the extrudate. The chamber ideally is mounted on the outside of the cooling-medium tank, between the extrusion die and the tank.

[0044] Tubular extrudate enters and exits the water-level controlled vacuum chamber, passing between a number of ultrasonic sensor/transducers that are immersed in the water in the chamber. The chamber is maintained under specific vacuum such that the entry and exit of the extrudate from the chamber prevents the water from exiting the chamber. The vacuum, namely sub-atmospheric pressure, in the chamber prevents water from leaking out of the chamber around the tubular extrudate where the tubular extrudate enters and exits the chamber; and the water serves as a hydraulic seal for the extrudate passing through the chamber. The chamber is necessarily sealed in order that the vacuum, i.e., sub-atmospheric pressure, may be maintained therein. The shorter distance (by virtue of the chamber ideally being mounted on the upstream exterior side of a cooling tank located essentially immediately adjacent to the die) from the hot die enhances potential tolerancing of the extrudate; can make it easier to center the die visually when correcting for non-concentricity of the tube and the die; and can eliminate any need to support the extrudate using contacting structures, such as rollers, as the extrudate passes through the chamber and the cooling-medium tank.

[0045] The chamber, and optionally the cooling-medium tank on which the chamber is mounted, can be mounted to be movable horizontally and vertically in response to signals generated by the ultrasonic sensor/transducers, so as to keep the chamber, and optionally the cooling-medium tank, in the proper position, with the extrudate being centered as it passes between pairs of the ultrasonic sensors/transducers as the extrusion process proceeds. The centering of the extrudate can automated, using the signals from the ultrasonic sensor/transducers; or may be performed manually, working from a video display generated from the signals received from the ultrasonic sensor/transducers.

[0046] Referring to the drawings in general and to FIG. 1 in particular, an ultrasonic extrusion control apparatus is illustrated in FIG. 1 and is designated generally using the reference character 10. Apparatus 10 includes an extruder 12 having an extrusion screw 14. Extruder 12 further includes a motor 16 that turns a drive shaft 18 connected to extruder screw 14 for rotation of extruder screw 14 during operation of the extruder 12.

[0047] As the extruder screw 14 rotates and thermoplastic polymeric material is fed to extruder screw 14 through a feed apparatus not illustrated in FIG. 1, the rotation of extruder screw 14 works the thermoplastic material and urges the thermoplastic material forward and to the right in FIG. 1, thereby turning the thermoplastic material into a highly-viscous, early molten material. Continued rotation of extruder screw 14 results in the highly-viscous thermoplastic material being forced through and out of an extruder die 20, with the viscous material assuming a shape according to the interior configuration of die 20. This extrudate, designated 22 in the drawings, is desirably tubular in structure. Most desirably, the extrudate 22 has a very thin wall and a very small central bore formed therein, as extrudate 22 exits die 20.

[0048] Shortly after exiting die 20, extrudate 22 enters a size vacuum chamber designated 26 in FIG. 1. Distance or space between die 20 and vacuum chamber 26 is referred to as hot die space and is designated generally 24 in FIG. 1. Note that hot die space 24 is not a structural element but rather denotes space traversed by extrudate 22 as it travels from die 20 to vacuum chamber 26.

[0049] Vacuum chamber 26 desirably is mounted on a cooling-medium tank 28, which can be either an open water tank or a closed vacuum tank, with an open water tank being preferable. Extrudate 22 passes through vacuum chamber 26 and through tank 28, all as illustrated in FIG. 1.

[0050] Extrudate 22 is pulled through vacuum chamber 26 and tank 28 by a puller assembly designated generally 30 in FIG. 1. Puller assembly 30 desirably constitutes two endless belts positioned in an opposed disposition with respect to one another, with extrudate 22 contacting the belts and being pulled from left to right in FIG. 1 by action by the endless belts. The belts of puller assembly 30 have not been numbered in FIG. 1, to enhance drawing clarity. Similarly, contact between extrudate 22 and the belts of puller assembly 30 has not been shown, to enhance drawing clarity.

[0051] After exiting puller assembly 30, extrudate 22 can enter a secondary cooling-medium tank 32, which is preferably filled with water. Secondary cooling-medium tank 32 is optional as indicated by the dotted line structure defining secondary cooling-medium tank 32 in FIG. 1. Extrudate 22 preferably resides within secondary cooling-medium tank 32 for a time sufficient to allow extrudate 22 to cool to a desired level so that the tubular structure of extrudate 22 is relatively fixed. Residence of extrudate 22 within secondary cooling-medium tank 32 may be via a curved path as illustrated in FIG. 1, or may be in a straight path. In any event, extrudate 22 eventually exits secondary cooling-medium tank 32 in a direction indicated by arrow B in FIG. 1.

[0052] FIG. 2 illustrates vacuum chamber 26, and components that are ancillary thereto and necessary for operation thereof, in more detail. Vacuum chamber 26 may be of any shape; the shape of vacuum chamber 26 is not critical. Vacuum chamber 26 has connected thereto a water pump shown schematically and designated 40 in FIG. 2. A vacuum pump 54 also is connected to vacuum chamber 26. Water pump 40 supplies water to the interior of vacuum chamber 26. Vacuum pump 54 draws air to create a sub-atmospheric pressure or vacuum within vacuum chamber 26 above the level of the water in the vacuum chamber 26. Water level in vacuum chamber 26 is indicated by water surface 34, which is a horizontal water surface within vacuum chamber 26.

[0053] Extrudate 22 enters vacuum chamber 26 traveling from left to right in FIG. 2. Openings in the vertical walls 56 of vacuum chamber 26 allow passage of extrudate 22 through the water contained within vacuum chamber 26. Due to the sub-atmospheric pressure maintained above water surface 34 by operation of vacuum pump 54, sub-atmospheric pressure is maintained within vacuum chamber 26. As a result, water does not escape from the openings in vertical walls 56 of vacuum chamber 26.

[0054] The vertical character of the water surfaces at the apertures of vertical walls 56 of vacuum chamber 26 is denoted by indicator numerals 36 in FIG. 2. A water level sensor 38 is provided within vacuum chamber 26 to monitor the level of horizontal water surface 34. Water level sensor 38 is connected to a vacuum/water level control 52 by suitable wiring, shown but not numbered in FIG. 2. Similarly, vacuum/water level control 52 connects to water pump 40 and to vacuum pump 54 by suitable electrical lines shown but not numbered in FIG. 2.

[0055] An ultrasonic transducer holder 48 is positioned within vacuum chamber 26 for passage therethrough of extrudate 22. Holder 48 holds a plurality of ultrasonic transducers 46. The ultrasonic transducers 46 are positioned to be in close proximity to extrudate 22 passing through vacuum chamber 26 and holder 48.

[0056] Referring to FIG. 3, holder 48 is shown in schematic form with four ultrasonic transducers 46 being positioned in holder 48, with ultrasonic transducers 46 being arranged in opposed pairs. The ultrasonic transducers 46 can be arranged in other configurations in alternative embodiments. Ultrasonic transducers 46 are in radial orientation with respect to extrudate 22. A bore 50 is provided in holder 48 for passage of extrudate 22 through holder 48.

[0057] As illustrated in FIG. 3, holder 48 is positioned so that ultrasonic transducers 46 are located below the level of the horizontal water surface 34 within vacuum chamber 26, and are fully immersed in the water. This is necessary to facilitate transmission of the ultrasonic waves that are emitted by the ultrasonic transducers 46 and reflected back toward the ultrasonic sensors 46 upon contact with the extrudate 22. Each ultrasonic transducer 46 generates an output signal indicative of the distance from the face of ultrasonic transducer 46 to the adjacent surface of the outer wall of the extrudate 22. The output signals of ultrasonic transducers 46 are provided to a suitable signal processing device for conversion into data regarding the size, i.e., the hot outer diameter, of extrudate 22; as well as the position of extrudate 22 in relation to the bore 50 in holder 48. The signal processing device is denoted in FIG. 4 by the reference character 60. The signal processing device 60 can be, for example, a UMAC measuring system available from Zumbach Electronic AG.

[0058] It is further within the scope of this technology to use ultrasonic transducers 46 as location devices to allow visual centering of the extrudate tube 22 as it passes through the transducer holder 48 and the tank 28. Specifically, signal processing device 60 is communicatively coupled to a video display 66, depicted schematically in FIG. 4. Signal processing device 60 is configured to process the outputs of ultrasonic transducers 46, and based on this processing, generate and display on video display 66 video images depicting the location of extrudate 22 in relation to ultrasonic transducers 46, and in relation to an established target defined by the centerline of the desired path of the extrudate 22 through the bore 50 of transducer holder 48, and cooling-medium tank 28. The displayed image can include cross hairs to indicate the centerline of the desired path of extrudate 22.

[0059] Cooling-medium tank 28 can be provided with provisions (not shown) that permit an operator to manually adjust the vertical and horizontal positions of tank 28, and the attached vacuum sensing chamber 26, in relation to extrudate 22. The operator can use these provisions in conjunction with the image displayed on video display 66 to adjust the position of cooling-medium tank 28 and vacuum sensing chamber 26 so as to align extrudate 22 and the desired path of extrudate 22 through transducer holder 48 and cooling-medium tank 28.

[0060] It is further within the scope of the disclosed technology to automate the adjustment of position of the vacuum sensing chamber 26 and cooling-medium tank 28. For example, FIGS. 2 and 4 depict a controller 70, and servo actuators 72. The controller 70 is communicatively coupled to servo actuators 72 and ultrasonic transducers 46. Controller 70 comprises a processor, such as a microprocessor; a memory having computer-executable instructions stored thereon; suitable input-output circuitry facilitating external communications between controller 70, servo actuators 72, and ultrasonic transducer 46; and a bus facilitating internal communications between the processor, the memory, and the input-output circuitry. The controller 70 can include other components, the disclosure of which is not necessary to an understanding of the disclosed technology.

[0061] The controller 70 receives a signal from signal processing device 60 indicating the position of extrudate 22 in relation to the desired path of travel of extrudate 22 through bore 50 of transducer holder 48, and cooling-medium tank 28. The computer executable instructions, when executed on the processor, cause the controller 70 to generate outputs to servo actuators 72 in response to the extrudate-position-information generated by signal processing device 60. The output of the controller 70 causes the servo actuators 72 to move tank 28, and the attached vacuum sensing chamber 26, horizontally and vertically so that the positions of transducer holder 40 the tank 28 are continuously adjusted to maintain the centerline of the extrudate 22 at the desired position in relation to the transducer holder 40 and tank 28 as the extrudate 22 passes through those components.

[0062] Such use of the ultrasonic transducers 46 as a location device, allowing manual visual, or automated centering of the extrudate 22 as it passes through the transducer holder 48 and vacuum sensing chamber 26, is believed to represent a significant advance over conventional practice. Under current conventional practice, it is extremely difficult to center the extrudate 22, which may be less than 0.01 inch in diameter as the extrudate 22 enters tooling at the entrance to a water or vacuum tank such as the tank 28.

[0063] In one of its manifestations, the technology may be considered as an ultrasonic transducer holder, which is a vacuum chamber unto itself, having a means of water entry, means of water exit, and a vacuum or suction port enabling vacuum to be drawn and thereby enabling water to be used as a hydraulic seal, with the vacuum being used at varying levels to control water flow out of the chamber and thus to control water and extrudate stability. The water level control is configured such that the water level is always controlled so that the sensing faces of ultrasonic transducers 46 are immersed in the water within the chamber. A closed loop vacuum system with an air/water separation filter is interfaced with the vacuum chamber 26 to enable stable operation. The differential pressure between the interior of the vacuum chamber 26 and the outer atmosphere is continuously adjusted so that the water in the vacuum chamber 26 will not come out of the vacuum chamber 26 no matter the atmospheric pressure at the locale at which the vacuum chamber 26 is in operation.

[0064] Configuring the structure in which transducers 46 reside asits own vacuum chamber 26 allows the vacuum chamber 26 to be mounted on the outside wall of a tank, such as the cooling-medium thank 28, at the extrudate entry aperture to the tank 28. In this manner, the ultrasonic transducers 26 and the vacuum chamber 26 can be positioned as close as possible to the extruder die 20 from which the extrudate 22 emerges.

[0065] An iris-type valve (not shown) can be used at the entrance and at the exit of the vacuum chamber 26, to minimize the space between the tubular extrudate 22 and the entry to the vacuum chamber 26 and thereby minimize the amount of any water that may escape in the event of a breakdown of the vacuum system and the resulting breakdown of the sub-atmospheric pressure within the chamber.

[0066] In one typical implementation of the technology, the length of a the vacuum chamber 26 through which the extrudate 22 travels may be as little as one inch or one and one-half inches. Minimizing the length of travel of the extrudate 22 through the water as the extrudate 22 passes the ultrasonic transducers 46 contributes to stability to extrudate 22, since the smaller the distance the extrudate 22 travels through the water, the less the flotation force on the extrudate 22. Minimizing the flotation force is desirable, because the flotation force tends to move the extrudate 22, which in turn can result in distortion and size variations in extrudate 22.

[0067] Because the vacuum sensing chamber 26 is closed, and is maintained at sub-atmospheric pressure, there is little or no potential for the water in the vacuum sensing chamber 26 to splash onto the face of the die 20, or onto the extrudate 22 as it exits the die 20. Such splashing, were it to occur, has the potential to introduce distortion and variations in the wall thickness of the hot extrudate 22 exiting the die 20. Given the absence of potential splashing from the closed vacuum sensing chamber 26, vacuum sensing chamber 26 can be positioned in close proximity to the die 20. For example, the entrance to vacuum sensing chamber 26 can be positioned about -inch from the face of the die 20.

[0068] Locating the entrance to vacuum sensing chamber 26 in close proximity to the die 20, in turn, can eliminate any need for rollers or other supports that contact extrudate 22 as extrudate 22 travels through vacuum sensing chamber 26 and the tank 28, because the die 20 remains close enough to act as a cantilever support for the extrudate 22. Thus, there is little if any potential for drag, and distortion and variations in the wall thickness of extrudate 22, caused by contact between the hot exudate 22 and a supporting structure.

[0069] Although schematic implementations of present technology and at least some of its advantages are described in detail hereinabove, it should be understood that various changes, substitutions and alterations may be made to the apparatus and methods disclosed herein without departing from the spirit and scope of the invention as defined by the appended claims. The disclosed embodiments are therefore to be considered in all respects as being illustrative and not restrictive with the scope of the technology being indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Moreover, the scope of this patent application is not intended to be limited to the particular implementations of apparatus and methods described in the specification, nor to any methods that may be described or inferentially understood by those skilled in the art to be present as described in this specification.

[0070] As disclosed above and from the foregoing description of exemplary embodiments of the technology, it will be readily apparent to those skilled in the art to which the technology pertains that the principles and particularly the compositions and methods disclosed herein can be used for applications other than those specifically mentioned. Further, as one of skill in the art will readily appreciate from the disclosure of the invention as set forth hereinabove, apparatus, methods, and steps presently existing or later developed, which perform substantially the same function or achieve substantially the same result as the corresponding embodiments described and disclosed hereinabove, may be utilized according to the description of the technology and the claims appended hereto. Accordingly, the appended claims are intended to include within their scope such apparatus, methods, and processes that provide the same result or which are, as a matter of law, embraced by the doctrine of the equivalents respecting the claims of this application.

[0071] As used in the claims appended hereto, the term comprising means including but not limited to, whereas the term consisting of means having only and no more, and the term consisting essentially of means having only and no more except for minor additions which would be known to one of skill in the art as possibly needed for operation of the invention. The scope of the appended claims, therefore, is indicated by the claims rather than by the foregoing description and all changes which come within the range of equivalency of the claims are to be considered to be embraced within the scope of the claims. Additional objects, other advantages, and further novel features of the technology will become apparent from study of the appended claims as well as from study of the foregoing detailed discussion and description of the preferred embodiments of the technology, as that study proceeds.