DEVICE FOR DETECTING THE SPEED AND THE LENGTH OF A CORRUGATED PIPE AND COILER MACHINE FOR PACKING CORRUGATED TUBES

Abstract

A device for detecting the speed and length of a corrugated pipe moving along a processing path includes a camera that, in use, is arranged at a non-zero distance from and facing the corrugated pipe. The camera is configured to capture images of at least a longitudinal portion of the corrugated pipe. A control module is operatively connected to the camera and configured to determine the feeding speed and the length of the corrugated pipe based on the images captured by the camera.

Claims

1. A device for detecting the speed and length of a corrugated pipe moving along a processing path, the device comprising: at least one camera positioned, in use, at a non-zero distance from and facing the corrugated pipe, wherein the camera is configured to capture images of at least a longitudinal portion of an outer surface of the corrugated pipe; a control module operatively connected to the camera to receive the images, wherein the control module is configured to: calculate a number of crests contained in the longitudinal portion of the corrugated pipe framed by the camera during a detection time window, and calculate both a feeding speed of the corrugated pipe and a length of the corrugated pipe based on the number of crests in the images detected by the camera.

2. The device according to claim 1, wherein the control module is configured to calculate the feeding speed of the corrugated pipe using the following formula: $\begin{array}{cc}v=\left(n_{R}d\right)/t& \left[1\right]\end{array}$ wherein: v is the feeding speed of the corrugated pipe, t is the detection time window, n.sub.R is the number of crests during the detection time window, and d is a distance between two successive crests.

3. The device according to claim 1, wherein the control module is configured to calculate the length of the corrugated pipe using the following formula: $\begin{array}{cc}L=L^{}+\left(n_{R}d\right)& \left[2\right]\end{array}$ wherein: L is an updated length of the corrugated pipe, L is a length of the corrugated pipe calculated in a previous detection time window, n.sub.R is the number of crests, and d is a distance between two successive crests.

4. The device according to claim 1, further comprising a back-lighting device positioned, in use, at a non-zero distance from and facing the corrugated pipe on an opposite side of the corrugated pipe with respect to the camera, wherein the back-lighting device is configured to back-light the longitudinal portion of the corrugated pipe framed by the camera.

5. A coiler machine for packing flexible corrugated pipes, the machine comprising: a coiling unit for forming a coil of corrugated pipe and arranged along a processing path; a feeding station arranged along the processing path upstream of the coiling unit and configured to supply the corrugated pipe continuously to the coiling unit; and the device according to claim 1 arranged at the feeding station.

6. The machine according to claim 5, further comprising: a control unit connected to the control module and configured to control the coiling unit based on the feeding speed and/or the length of the corrugated pipe.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] The disclosure will now be described with reference to the accompanying drawings, which show some non-limiting examples of embodiments.

[0012] FIG. 1 is a schematic side view, with parts removed for clarity, of a coiler machine made in accordance with the present disclosure.

[0013] FIG. 2 is a schematic view, with parts removed for clarity, of a device for detecting the speed and/or length of a corrugated pipe made in accordance with the present disclosure.

[0014] FIG. 3 represents an image detected by an optical sensor of the detection device of FIG. 2.

DETAILED DESCRIPTION OF THE DISCLOSURE

[0015] In FIG. 1, reference numeral 1 denotes, as a whole, a coiler machine for packing a flexible corrugated pipe 2.

[0016] The corrugated pipe 2 is defined by alternating crests (or ridges) C having a constant width indicated with a and grooves G (or valleys) having a constant width indicated with b. The distance between two crests is given by the sum of the length a and the length b and defines the corrugation pitch of the corrugated pipe 2. The corrugated pipe 2 moves along a processing path P.

[0017] The coiler machine 1 comprises a plurality of operating stations that develop along the processing path P. More in detail, the coiler machine 1 comprises a coiling unit 3 of known type for the formation of a coil (not shown) of corrugated pipe 2; a packaging unit 4 arranged downstream of the coiling unit 3 along the processing path P and configured to tie with a strap and/or wrap the plastic film around the coil of corrugated pipe 2; and an outlet station 5 for the coils of corrugated pipe 2 arranged downstream of the packaging unit 4 along the processing path P.

[0018] The coiler machine 1 then comprises a feeding station 6 arranged upstream of the coiling unit 3 along the processing path P. The feeding station 6 is configured to continuously supply the corrugated pipe 2 from an extrusion unit (not shown) into the coiling unit 3. Finally, the coiler machine 1 comprises a base 7 that supports the feeding station 6, and inside which the coiling unit 3 and the packaging unit 4 are housed.

[0019] The feeding station 6 comprises an inlet cone 8 supported by the base 7 and configured to receive the corrugated pipe 2 and feed it to the coiling unit 3.

[0020] The coiler machine 1 comprises a control apparatus 9 having at least one electronic control unit CU configured to supervise the operation of the coiler machine 1.

[0021] The control apparatus 9 comprises a detection device 10. The detection device 10 is arranged along the processing path P; more in detail, the detection device 10 is arranged in the area of the feeding station 6. The detection device 10 is configured to detect the feeding speed v and/or the length L of the corrugated pipe 2.

[0022] The detection device 10 comprises at least one (optical) sensor 11 configured to frame at least a longitudinal portion of the corrugated pipe 2. Advantageously, the sensor 11 is of the non-contact type. Advantageously, the sensor 11 is a camera 11. In use, the camera 11 is arranged in a position facing the corrugated pipe 2. In use, the camera 11 is arranged at a non-zero distance from the corrugated pipe 2.

[0023] Preferably, the longitudinal portion of the corrugated pipe 2 framed by the camera 11 comprises a number of crests C and grooves G. Even more preferably, the longitudinal portion of the corrugated pipe 2 framed by the camera 11 comprises a plurality (at least two) of crests C and grooves G. Depending on the dimensions of the corrugated pipe 2, the camera 11 is arranged to frame the entire section of the longitudinal portion of the corrugated pipe 2 or, alternatively, exclusively a portion of the section of the longitudinal portion of the corrugated pipe 2 (clearly, the portion provided with the crests C and grooves G).

[0024] The detection device 10 further comprises at least one back-lighting device 12. In use, the back-lighting device 12 is also arranged in a position facing the corrugated pipe 2. In use, the back-lighting device 12 is arranged at a non-zero distance from the corrugated pipe 2. More in detail, when in use, the back-lighting device 12 and the camera 11 are arranged on opposite sides of the corrugated pipe 2; in other words, the corrugated pipe 2 advances in the direction indicated with D and is interposed between the back-lighting device 12 and the camera 11. The back-lighting device 12 is configured to (back)-light the longitudinal portion of the corrugated pipe 2 framed by the camera 11. The presence of the back-lighting device 12 makes it easier to detect the shape of the corrugated pipe 2 defined by the alternation of the crests C and the grooves G.

[0025] The detection device 10 finally comprises a control module 13. The control module 13 is configured to receive the signals from the camera 11 and to determine the feeding speed v of the corrugated pipe 2 and the length L of the corrugated pipe 2 based on the signals.

[0026] More in detail, the control module 13 is configured to: calculate the number n.sub.R of crests C contained in the longitudinal portion of the corrugated pipe 2 framed by the camera 11 during a detection time window t; and calculate the feeding speed v of the corrugated pipe 2 and/or the length L of the corrugated pipe 2 based on the number n.sub.R of crests C (contained in the longitudinal portion of the corrugated pipe 2 framed by the camera 11 during a detection time window t).

[0027] More in detail, the control module 13 is configured to calculate the feeding speed v of the corrugated pipe 2 by means of the following formula:

[00001]$\begin{array}{cc}v=\left(n_{R}d\right)/t& \left[1\right]\end{array}$

[0028] wherein [0029] V feeding speed of the corrugated pipe 2; [0030] t detection time window; [0031] n.sub.R number of crests C during the detection time window t; and [0032] d distance between two successive crests C.

[0033] Furthermore, the control module 13 is configured to calculate the length L of the corrugated pipe 2 by means of the following formula:

[00002]$\begin{array}{cc}L=L^{}+\left(n_{R}d\right)& \left[2\right]\end{array}$

[0034] wherein [0035] L updated length of the corrugated pipe 2; [0036] L length of the corrugated pipe 2 calculated in the previous detection time window t; [0037] n.sub.R number of crests; and [0038] d distance between two successive crests C.

[0039] The detection time window t has a constant amplitude, which is determined in a preliminary step of tuning the detection device 10.

[0040] Advantageously, the distance d between two crests C is also determined in a preliminary step of tuning the detection device 10. Preferably, maps providing the distance d between two successive crests C based on a number of parameters are stored within the control module 13; in particular, the parameters include the diameter of the corrugated pipe 2.

[0041] The number n.sub.R of crests is determined through a processing of the images detected by the camera 11 during the detection time window t. Advantageously, the control module 13 is configured to: capture during the detection time window t a number of images (frames) detected by the camera 11; optionally convert each image captured into grayscale (in the event that the image has not already been initially captured in grayscale); construct a binary image from each grayscale image; in each binary image each pixel is associated with the black colour if the pixel is within the shape of the corrugated pipe 2 or alternatively the white colour; and detect the number of black pixels in at least one control segment of each binary image.

[0042] Finally, the control module 13 is configured to calculate the number n.sub.R of crests during the detection time window t based on the number of black pixels in the control segments of the binary images.

[0043] The control module 13 is connected to the control unit CU, to which it transmits a signal indicative of the feeding speed v of the corrugated pipe 2 and the length L of the corrugated pipe. The control unit CU is then configured to control the coiling unit 3 based on the signals transmitted by the control module 13; in particular based on the length of corrugated pipe 2 coiled; more in detail, the control unit CU is configured to determine when a predefined length of corrugated pipe 2 has been reached based on a length of the coil to be coiled.

[0044] Advantageously, the control module 13 is integrated into the camera 11 and is connected to the control unit CU with which it communicates. Alternatively, the control module 13 is integrated into the control unit CU and is connected to the camera 11 with which it communicates.

[0045] The feeding station 6 further comprises a support structure 14 having at least a first bracket (not shown) supporting the camera 11 and at least a second bracket (not shown) supporting the back-lighting device 12.

[0046] According to a preferred embodiment, the detection device 10 comprises support elements 15 of the corrugated pipe 2. The support elements 15 are configured to support the corrugated pipe 2 in the passage between the camera 11 and the back-lighting device 12 so as to contain the oscillations of the corrugated pipe 2 within the reading range of the camera 11. The support elements 15 comprise a number of rollers 16 configured to support and guide the corrugated pipe 2 through the feeding station 6. Preferably, (not exclusively) the support elements 15 comprise a number of biconical rollers 16 configured to support the corrugated pipe 2. The biconical rollers 16 are provided with axes parallel to each other.

[0047] More in detail, the support elements 15 comprise a plurality of biconical rollers 16, in particular four biconical rollers 16; preferably, the four biconical rollers 16 are divided into two pairs of biconical rollers 16. A (first) pair of biconical rollers 16 is arranged at the inlet of the feeding station 6 with a (first) biconical roller 16A arranged below the corrugated pipe 2 and a (second) biconical roller 16B arranged above the corrugated pipe 2. A (second) pair of biconical rollers 16 is arranged at the outlet of the feeding station 6 with a (third) biconical roller 16C arranged below the corrugated pipe 2 and a (fourth) biconical roller 16D arranged above the corrugated pipe 2.

[0048] Alternatively, the support elements 15 comprise a plurality of biconical rollers 16, in particular, two biconical rollers 16. A (first) biconical roller 16A is arranged at the inlet of the feeding station 6 below the corrugated pipe 2, and a (second) biconical roller 16C is arranged at the outlet of the feeding station 6 below the corrugated pipe 2.

[0049] According to a further variant, the support elements 15 comprise a number of shaped flat metal sheets and are preferably coated with a low-friction coefficient material.

[0050] In the preceding discussion, explicit reference has been made to the case of a coiler machine 1, but the detection device 10 can also find advantageous application in other machines, for example, in machines for cutting corrugated pipes 2.

[0051] It is important to point out that in the detection device 10 described in the preceding discussion, there are no sensors dedicated to the detection of the feeding speed v; on the contrary, both the feeding speed v and the length L of the corrugated pipe 2 are determined through the images detected by the camera 11.

[0052] The detection device 10 and the coiler machine 1 described in the preceding discussion have some advantages; in particular, the detection device 10 needs a rather rapid setting and tuning step, can be easily adapted to different types and dimensions of corrugated pipe 2 (only specifying the distance between two successive crests C) and guarantees a reliable and robust measurement of both the feeding speed v, even in the case of variable feeding speeds v, and the length L of the corrugated pipe 2 regardless of the environmental conditions and the oscillations and deformations to which the corrugated pipe 2 is subjected.

LIST OF REFERENCE NUMBERS

[0053] 1 coiler machine [0054] 2 corrugated pipe [0055] 3 coiling unit [0056] 4 packing unit [0057] 5 outlet station [0058] 6 feeding station [0059] 7 base [0060] 8 inlet cone [0061] 9 control apparatus [0062] 10 detection device [0063] 11 camera [0064] 12 back-lighting device [0065] 13 control module [0066] 14 support structure [0067] 15 support elements [0068] 16A roller [0069] 16B roller [0070] 16C roller [0071] 16D roller [0072] C crest [0073] G groove [0074] a width [0075] b width [0076] P path [0077] CU control unit [0078] D direction