ACCURATE ROLLING LINE ALIGNMENT FOR FORMING ALUMINUM HEAT EXCHANGERS

Abstract

A method for controlling an adjustable rolling line includes obtaining, while the line is operating, a first measurement of a first convolution spacing of first corrugated material formed from coiled material by a pair of primary rollers and one or more adjustable finger tensioners, determining, based on the first measurement, one or more first adjustments to the one or more adjustable finger tensioners, and adjusting, based on the one or more first adjustments, the one or more adjustable finger tensioners. The method also includes obtaining, while the line is operating, a second measurement of a second convolution spacing of second corrugated material formed from the first corrugated material by a pair of adjustable restrike rollers, determining, based on the second measurement, one or more second adjustments to the pair of adjustable restrike rollers, and adjusting, based on the one or more second adjustments, the pair of adjustable restrike rollers.

Description

INTRODUCTION

The information provided in this section is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.

Aluminum roll forming is a continuous bending operation in which a long strip of aluminum, typically coiled aluminum, is passed through consecutive sets of rollers, finger tensioners, or stands, each performing only an incremental part of the bend, until a desired cross-sectional profile (e.g., corrugated material having a pre-determined convolution spacing) is obtained. Aluminum roll forming is widely used in various industries, including automotive, construction, and aerospace, due to its ability to produce lightweight, durable, and corrosion-resistant components.

The present disclosure relates generally to accurate rolling line alignment for forming aluminum heat exchangers.

SUMMARY

One aspect of the disclosure provides an adjustable rolling line including a spool configured to hold coiled material, a pair of primary rollers, one or more adjustable finger tensioners, a first measurement device, a pair of adjustable restrike rollers, and a second measurement device. The pair of primary rollers is configured to form first corrugated material from the coiled material, the first corrugated material having a first convolution spacing. The one or more adjustable finger tensioners are configured to form second corrugated material from the first corrugated material, the second corrugated material having a second convolution spacing. The first measurement device is configured to measure, while the adjustable rolling line is operating, a measurement of the second convolution spacing. The pair of adjustable restrike rollers is configured to form third corrugated material from the second corrugated material for a heat exchanger for a vehicle, the third corrugated material having a third convolution spacing. The second measurement device is configured to measure, while the adjustable rolling line is operating, a measurement of the third convolution spacing. The adjustable rolling line also includes data processing hardware, and memory hardware in communication with the data processing hardware and storing instructions that, when executed by the data processing hardware, cause the data processing hardware to perform operations. The operations include determining, based on the measurement of the second convolution spacing, one or more first adjustments to the one or more adjustable finger tensioners, adjusting, based on the one or more first adjustments, the one or more adjustable finger tensioners, determining, based on the measurement of the third convolution spacing, one or more second adjustments to the pair of adjustable restrike rollers, and adjusting, based on the one or more second adjustments, the pair of adjustable restrike rollers.

Implementations of the disclosure may include one or more of the following optional features. In some implementations, the first measurement device includes at least one of a laser, a camera, or a proximity sensor configured to measure distances to the second corrugated material, wherein the distances can be processed to determine, as the measurement of the second convolution spacing, distances between peaks of the second corrugated material. In some examples, the one or more first adjustments to the one or more adjustable finger tensioners include one or more of a position adjustment to a horizontal position of a first finger tensioner of the one or more adjustable finger tensioners, a height adjustment to a vertical position of the first finger tensioner of the one or more adjustable finger tensioners, or an angle adjustment to an angle of the first finger tensioner of the one or more adjustable finger tensioners. In some implementations, the adjustable rolling line also includes at least one adjustment component, wherein adjusting, based on the one or more first adjustments, the one or more adjustable finger tensioners includes controlling the at least one adjustment component to make the position adjustment, the height adjustment, and/or the angle adjustment.

In some examples, the second measurement device includes at least one of a laser, a camera, or a proximity sensor configured to measure distances to the third corrugated material, wherein the distances can be processed to determine, as the measurement of the third convolution spacing, distances between peaks of the third corrugated material. In some implementations, the one or more second adjustments to the pair of adjustable restrike rollers includes one or more of a position adjustment to a horizontal position of a first restrike roller of the pair of adjustable restrike rollers, or a height adjustment to a vertical position of the first restrike roller of the pair of adjustable restrike rollers. In some examples, the adjustable rolling line also includes at least one adjustment component, wherein adjusting, based on the one or more second adjustments, the pair of adjustable restrike rollers includes controlling the at least one adjustment component to make the position adjustment and/or the height adjustment.

In some implementations, the adjustable rolling line also includes a strobe light configured to emit pulsed light at a frequency corresponding a pre-determined corrugation period to provide a visual indication of whether the second convolution spacing and/or the third convolution spacing equals the pre-determined corrugation period. In some examples, the operations also include determining that a portion of the third corrugated material has a fourth convolution spacing that does not satisfy a pre-determined convolution spacing tolerance and, based on determining that the portion of the third corrugated material has the fourth convolution spacing that does not satisfy the pre-determined convolution spacing tolerance, diverting the portion of the third corrugated material to scrap.

In some examples, the operations also include obtaining a coil lot specification for the coiled material, determining, based on the coil lot specification, one or more first settings of the one or more adjustable finger tensioners, adjusting, based on the one or more first settings, the one or more adjustable finger tensioners, determining, based on the coil lot specification, one or more second settings of the pair of adjustable restrike rollers, and adjusting, based on the one or more second settings, the pair of adjustable restrike rollers. In some implementations, the operations also include displaying for an operator of the adjustable rolling line the first measurement and the second measurement.

In some implementations, determining, based on the measurement of the second convolution spacing, the one or more first adjustments to the one or more adjustable finger tensioners includes determining the one or more first adjustments to maintain the second convolution spacing within a first pre-determined convolution spacing range, and determining, based on the measurement of the third convolution spacing, the one or more second adjustments to the pair of adjustable restrike rollers includes determining the one or more second adjustments to maintain the third convolution spacing within a second pre-determined convolution spacing range.

Another aspect of the disclosure provides a method for controlling an adjustable rolling line. The method includes obtaining, while the adjustable rolling line is operating, a first measurement of a first convolution spacing of first corrugated material formed from coiled material by a pair of primary rollers and one or more adjustable finger tensioners, determining, based on the first measurement, one or more first adjustments to the one or more adjustable finger tensioners, and adjusting, based on the one or more first adjustments, the one or more adjustable finger tensioners. The method also includes obtaining, while the adjustable rolling line is operating, a second measurement of a second convolution spacing of second corrugated material formed from the first corrugated material by a pair of adjustable restrike rollers, determining, based on the second measurement, one or more second adjustments to the pair of adjustable restrike rollers, and adjusting, based on the one or more second adjustments, the pair of adjustable restrike rollers.

Implementations of the disclosure may include one or more of the following optional features. In some implementations, the one or more first adjustments to the one or more adjustable finger tensioners include one or more of a position adjustment to a horizontal position of a first finger tensioner of the one or more adjustable finger tensioners, a height adjustment to a vertical position of the first finger tensioner of the one or more adjustable finger tensioners, or an angle adjustment to an angle of the first finger tensioner of the one or more adjustable finger tensioners. In some examples, the one or more second adjustments to the pair of adjustable restrike rollers include one or more of a position adjustment to a horizontal position of a first restrike roller of the pair of adjustable restrike rollers, or a height adjustment to a vertical position of the first restrike roller of the pair of adjustable restrike rollers.

In some examples, the method also includes determining that a portion of the second corrugated material has a third convolution spacing that does not satisfy a pre-determined convolution spacing tolerance and, based on determining that the portion of the second corrugated material has the third convolution spacing that does not satisfy the pre-determined convolution spacing tolerance, diverting the portion of the second corrugated material to scrap. In some implementations, the method also includes obtaining a coil lot specification for the coiled material, determining, based on the coil lot specification, one or more first settings of the one or more adjustable finger tensioners, adjusting, based on the one or more first settings, the one or more adjustable finger tensioners, determining, based on the coil lot specification, one or more second settings of the pair of adjustable restrike rollers, and adjusting, based on the one or more second settings, the pair of adjustable restrike rollers.

Yet another aspect of the disclosure provides a system including data processing hardware, and memory hardware in communication with the data processing hardware and storing instructions that, when executed by the data processing hardware, cause the data processing hardware to perform operations. The operations include obtaining, while an adjustable rolling line is operating, a first measurement of a first convolution spacing of first corrugated material formed from coiled material by a pair of primary rollers and one or more adjustable finger tensioners, determining, based on the first measurement, one or more first adjustments to the one or more adjustable finger tensioners, and adjusting, based on the one or more first adjustments, the one or more adjustable finger tensioners. The operations also include obtaining, while the adjustable rolling line is operating, a second measurement of a second convolution spacing of second corrugated material formed from the first corrugated material by a pair of adjustable restrike rollers, determining, based on the second measurement, one or more second adjustments to the pair of adjustable restrike rollers, and adjusting, based on the one or more second adjustments, the pair of adjustable restrike rollers.

Implementations of the disclosure may include one or more of the following optional features. In some implementations, the operations also include determining that a portion of the second corrugated material has a third convolution spacing that does not satisfy a pre-determined convolution spacing tolerance and, based on determining that the portion of the second corrugated material has the third convolution spacing that does not satisfy the pre-determined convolution spacing tolerance, diverting the portion of the second corrugated material to scrap. In some examples, the operations also include obtaining a coil lot specification for the coiled material, determining, based on the coil lot specification, one or more first settings of the one or more adjustable finger tensioners, adjusting, based on the one or more first settings, the one or more adjustable finger tensioners, determining, based on the coil lot specification, one or more second settings of the pair of adjustable restrike rollers, and adjusting, based on the one or more second settings, the pair of adjustable restrike rollers.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.

FIG. 1 is a schematic view of an example adjustable rolling line for forming corrugated material for a heat exchanger for a vehicle.

FIG. 2 is a flow chart of an example arrangement of operations for a method of controlling an adjustable rolling line for forming corrugated material for an aluminum heat exchanger for a vehicle.

FIG. 3 is a flow chart of an example arrangement of operations for a method of controlling an adjustable rolling line for forming corrugated material for an aluminum heat exchanger for a vehicle.

FIG. 4 is a schematic view of an example computing device that may be used to implement the systems and methods described herein.

Corresponding reference numerals indicate corresponding parts throughout the drawings.

DETAILED DESCRIPTION

Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.

The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,” “connected to,” “attached to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” “directly attached to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

The terms “first,” “second,” “third,” etc. may be used herein to describe various elements, components, regions, layers and/or sections. These elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example configurations.

In this application, including the definitions below, the term “module” may be replaced with the term “circuit.” The term “module” may refer to, be part of, or include an Application Specific Integrated Circuit (ASIC); a digital, analog, or mixed analog/digital discrete circuit; a digital, analog, or mixed analog/digital integrated circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor (shared, dedicated, or group) that executes code; memory (shared, dedicated, or group) that stores code executed by a processor; other suitable hardware components that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip.

The term “code,” as used above, may include software, firmware, and/or microcode, and may refer to programs, routines, functions, classes, and/or objects. The term “shared processor” encompasses a single processor that executes some or all code from multiple modules. The term “group processor” encompasses a processor that, in combination with additional processors, executes some or all code from one or more modules. The term “shared memory” encompasses a single memory that stores some or all code from multiple modules. The term “group memory” encompasses a memory that, in combination with additional memories, stores some or all code from one or more modules. The term “memory” may be a subset of the term “computer-readable medium.” The term “computer-readable medium” does not encompass transitory electrical and electromagnetic signals propagating through a medium, and may therefore be considered tangible and non-transitory memory. Non-limiting examples of a non-transitory memory include a tangible computer readable medium including a nonvolatile memory, magnetic storage, and optical storage.

The apparatuses and methods described in this application may be partially or fully implemented by one or more computer programs executed by one or more processors. The computer programs include processor-executable instructions that are stored on at least one non-transitory tangible computer readable medium. The computer programs may also include and/or rely on stored data.

A software application (i.e., a software resource) may refer to computer software that causes a computing device to perform a task. In some examples, a software application may be referred to as an “application,” an “app,” or a “program.” Example applications include, but are not limited to, system diagnostic applications, system management applications, system maintenance applications, word processing applications, spreadsheet applications, messaging applications, media streaming applications, social networking applications, and gaming applications.

The non-transitory memory may be physical devices used to store programs (e.g., sequences of instructions) or data (e.g., program state information) on a temporary or permanent basis for use by a computing device. The non-transitory memory may be volatile and/or non-volatile addressable semiconductor memory. Examples of non-volatile memory include, but are not limited to, flash memory and read-only memory (ROM)/programmable read-only memory (PROM)/erasable programmable read-only memory (EPROM)/electronically erasable programmable read-only memory (EEPROM) (e.g., typically used for firmware, such as boot programs). Examples of volatile memory include, but are not limited to, random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), phase change memory (PCM) as well as disks or tapes.

These computer programs (also known as programs, software, software applications or code) include machine instructions for a programmable processor, and can be implemented in a high-level procedural and/or object-oriented programming language, and/or in assembly/machine language. As used herein, the terms “machine-readable medium” and “computer-readable medium” refer to any computer program product, non-transitory computer readable medium, apparatus and/or device (e.g., magnetic discs, optical disks, memory, Programmable Logic Devices (PLDs)) used to provide machine instructions and/or data to a programmable processor, including a machine-readable medium that receives machine instructions as a machine-readable signal. The term “machine-readable signal” refers to any signal used to provide machine instructions and/or data to a programmable processor.

Various implementations of the systems and techniques described herein can be realized in digital electronic and/or optical circuitry, integrated circuitry, specially designed ASICs (application specific integrated circuits), computer hardware, firmware, software, and/or combinations thereof. These various implementations can include implementation in one or more computer programs that are executable and/or interpretable on a programmable system including at least one programmable processor, which may be special or general purpose, coupled to receive data and instructions from, and to transmit data and instructions to, a storage system, at least one input device, and at least one output device.

The processes and logic flows described in this specification can be performed by one or more programmable processors, also referred to as data processing hardware, executing one or more computer programs to perform functions by operating on input data and generating output. The processes and logic flows can also be performed by special purpose logic circuitry, e.g., an FPGA (field programmable gate array) or an ASIC (application specific integrated circuit). Processors suitable for the execution of a computer program include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, a processor will receive instructions and data from a read only memory or a random access memory or both. The essential elements of a computer are a processor for performing instructions and one or more memory devices for storing instructions and data. Generally, a computer will also include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data, e.g., magnetic, magneto optical disks, or optical disks. However, a computer need not have such devices. Computer readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media and memory devices, including by way of example semiconductor memory devices, e.g., EPROM, EEPROM, and flash memory devices; magnetic disks, e.g., internal hard disks or removable disks; magneto optical disks; and CD ROM and DVD-ROM disks. The processor and the memory can be supplemented by, or incorporated in, special purpose logic circuitry.

To provide for interaction with a user, one or more aspects of the disclosure can be implemented on a computer having a display device, e.g., a CRT (cathode ray tube), LCD (liquid crystal display) monitor, or touch screen for displaying information to the user and optionally a keyboard and a pointing device, e.g., a mouse or a trackball, by which the user can provide input to the computer. Other kinds of devices can be used to provide interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback, e.g., visual feedback, auditory feedback, or tactile feedback; and input from the user can be received in any form, including acoustic, speech, or tactile input. In addition, a computer can interact with a user by sending documents to and receiving documents from a device that is used by the user; for example, by sending web pages to a web browser on a user's client device in response to requests received from the web browser.

Unless expressly stated to the contrary, the phrase “at least one of A, B, or C” is intended to refer to any combination or subset of A, B, C such as: (1) at least one A alone; (2) at least one B alone; (3) at least one C alone; (4) at least one A with at least one B; (5) at least one A with at least one C; (6) at least one B with at least C; and (7) at least one A with at least one B and at least one C. Moreover, unless expressly stated to the contrary, the phrase “at least one of A, B, and C” is intended to refer to any combination or subset of A, B, C such as: (1) at least one A alone; (2) at least one B alone; (3) at least one C alone; (4) at least one A with at least one B; (5) at least one A with at least one C; (6) at least one B with at least one C; and (7) at least one A with at least one B and at least one C. Furthermore, unless expressly stated to the contrary, “A or B” is intended to refer to any combination of A and B, such as: (1) A alone; (2) B alone; and (3) A and B.

Aluminum roll forming is a continuous bending operation in which a long strip of aluminum, typically coiled aluminum, is passed through consecutive sets of rollers, finger tensioners or stands, each performing only an incremental part of the bend, until a desired cross-section profile (e.g., corrugated material having a pre-determined convolution spacing) is obtained. Aluminum roll forming is widely used in various industries, including automotive, construction, and aerospace, due to its ability to produce lightweight, durable, and corrosion-resistant components. For example, to form corrugated material for an aluminum heat exchanger for a vehicle. However, improper alignment or wear of the rollers, finger tensioners or stands can cause dimensional inaccuracies. For example, when the convolution spacing of corrugated material becomes too large or too tight, restrike rollers may no longer be aligned with the convolutions, such that the restrike rollers fold over the peaks of the corrugated material. Such inaccuracies may result in corrugated material that has to be discarded or line stoppages to effect rolling line adjustments. Therefore, there is a need for methods and systems for aligning rolling lines to reduce scrap and increase throughput. In disclosed implementations, the convolution spacing of corrugated material being formed by an adjustable rolling line is measured and tracked in real time, and feedback control is used to make one or more automated adjustments to components of the adjustable rolling line to maintain the convolution spacing within a pre-determined convolution spacing tolerance or range. In some examples, the adjustments are made while the adjustable rolling line operates, that is, without stopping the adjustable rolling line.

While configurations are shown and described herein in connection with forming corrugated material for forming an aluminum heat exchanger for a vehicle (e.g., an automobile, a truck, an airplane, a train, a motorcycle, a drone, etc.), it should be understood that disclosed configurations may additionally, or alternatively, be used to accurately track and automatically adjust a rolling line for forming other parts.

FIG. 1 is a schematic view of an example adjustable rolling line 100 for forming corrugated material 142 for an aluminum heat exchanger for a vehicle (e.g., an automobile, a truck, an airplane, a train, a motorcycle, a drone, etc.). The adjustable rolling line 100 includes a spool 110 configured to hold coiled flat aluminum material 112 from which the corrugated material 142 will be formed. The adjustable rolling line 100 also includes a pair of primary rollers 120, 120a-b configured to form first corrugated material 122 from the coiled flat aluminum material 112. Here, the first corrugated material 122 has a first convolution spacing. A convolution spacing represents a distance between peaks or between valleys of a corrugated material. The adjustable rolling line 100 additionally includes one or more adjustable finger tensioners 130, 130a-n configured to form second corrugated material 132 from the first corrugated material 122. Here, the second corrugated material 132 has a second convolution spacing. The adjustable rolling line 100 further includes a pair of adjustable restrike rollers 140, 140a-b configured to form third corrugated material 142 from the second corrugated material 132 for a heat exchanger for a vehicle. Here, the third corrugated material 142 has a third convolution spacing. While an example adjustable rolling line 100 is shown in FIG. 1, a rolling line may have any number and/or type(s) of additional or alternative components. For example, a rolling line may include one or more additional pairs of primary rollers that proceed the pair of primary rollers 120, and/or one or more additional pairs of restrike rollers that follow the restrike rollers 140.

In the illustrated example of FIG. 1, the one or more adjustable finger tensioners 130 are each individually adjustable in one or more of a horizontal position (e.g., left or right in the orientation of FIG. 1), an angle, or a vertical position (e.g., up or down in the orientation of FIG. 1). The adjustable restrike rollers 140 are similarly individually adjustable in one or more of a horizontal position (e.g., left or right in the orientation of FIG. 1), a vertical position (e.g., up or down in the orientation of FIG. 1), a rotational position, or a speed. In some examples, the adjustable rolling line 100 includes one or more adjustment components such as, but not limited to, a rack and pinion, a roller pinion, an actuator, a pneumatic linear actuator, a ball screw linear actuator, a hydraulic actuator, a rotary actuator, or a magnetic servo (not shown for clarity of illustration) for making a respective one of each of the individual adjustments.

The adjustable rolling line 100 also includes one or more measurement devices 150, 150a-n configured to, while the adjustable rolling line 100 operates, measure measurements of convolution spacings of the corrugated materials 122, 132, and 142. In the illustrated example, the measurement device 150a measures distances from the measurement device 150a to the second corrugated material 132 that can be processed to determine, as a measurement of a convolution spacing of the second corrugated material 132, distances between peaks or between valleys of the corrugated material 132. The measurement device 150b similarly measures distances form the measurement device 150b to the third corrugated material 142 that can be processed to determine, as a measurement of a convolution spacing of the third corrugated material 142, distances between peaks or between valleys of the corrugated material 142. In some implementations, the measurements devices 150 include, for example, lasers, cameras, or proximity sensors for measuring, determining, or sensing distances to the corrugated materials 122, 132, and 142. In some examples, the measurements of convolution spacings of the corrugated materials 122, 132, and 142 are displayed for an operator of the adjustable rolling line 100.

The adjustable rolling line 100 also includes one or more computing systems 400 (see FIG. 4) for controlling and adjusting the adjustable rolling line 100 either while the adjustable rolling line 100 is operating or while the adjustable rolling line 100 is stopped. The computing system 400 may correspond to any type of computing device, such as a process controller. The computing system 400 includes data processing hardware 410, and memory hardware 420 in communication with the data processing hardware 410. Here, the memory hardware 420 stores instructions that, when executed by the data processing hardware 410, cause the data processing hardware 410 to perform one or more operations, such as those disclosed herein.

The memory hardware 420 stores instructions that, when executed by the data processing hardware 410, cause the data processing hardware 410 to perform operations. The operations may include determining, based on a measurement by the measurement device 150a, one or more adjustments to the one or more adjustable finger tensioners 130, and adjusting, based the one or more adjustments, the one or more adjustable finger tensioners 130. Here, the one or more adjustments may include a position adjustment to a horizontal position of one or more of the adjustable finger tensioners 130, a height adjustment to a vertical position of one or more of the adjustable finger tensioners 130, or an angle adjustment to an angle of one or more of the adjustable finger tensioners 130. The one or more adjustments to the one or more adjustable finger tensioners 130 may be determined to maintain a convolution spacing of the corrugated material 132 within a pre-determined convolution spacing range or tolerance.

Additionally, or alternatively, the operations may include determining, based on a second measurement by the measurement device 150b, one or more adjustments to the pair of adjustable restrike rollers 140, and adjusting, based the one or more adjustments, the pair of adjustable restrike rollers 140. Here, the one or more adjustments may include a position adjustment to a horizontal position of one or more of the adjustable restrike rollers 140, a height adjustment to a vertical position of one or more of the adjustable restrike rollers 140, a rotational position, or a speed. The one or more adjustments to the one or more adjustable restrike rollers 140 may be determined to maintain a convolution spacing of the corrugated material 142 within a pre-determined convolution spacing range or tolerance, which may be different from the pre-determined convolution spacing range or tolerance for the adjustable finger tensioners 130.

In some implementations, if the convolution spacing of the corrugated material 132 is too small, the computing system 400 determines adjustments that:

• • increase tensioning finger force/pressure by lowering the tensioning fingers 130 and rotating the tensioning fingers 130 opposite the direction of feed;
  • increase the phase between the restrike rollers 140 and the tensioning fingers 130 (e.g., by momentarily increasing the speed of the restrike rollers 140) and rotating the restrike rollers 140 to put more pull into the convolutions; and/or
  • move/shift the restrike rollers 140 away from the tensioning fingers 130.

In some implementations, if the convolution spacing of the corrugated material 132 is too large, the computing system 400 determines adjustments that:

• • decrease tensioning finger force/pressure by raising the tensioning fingers 130, and rotating the tensioning fingers 130 in the direction of feed;
  • decrease the phase between the restrike rollers 140 and the tensioning fingers 130 (e.g., by momentarily decreasing the speed of the restrike rollers 140) and rotating the restrike rollers 140 to put less pull into the convolution; and/or
  • move/shift the restrike rollers 140 toward the tensioning fingers 130.

In some implementations, if the convolution spacing of the corrugated material 142 is too small, the computing system 400 determines adjustments that:

• • increase the phase between a second pair of restrike rollers (that follow the restrike rollers 140) and the restrike rollers 140 (e.g., by momentarily increasing the speed of the second restrike rollers) and rotating the second restrike rollers to put more pull into the convolutions;
  • move/shift the second restrike rollers away from the restrike rollers 140.
  • lower the restrike rollers 140.

In some implementations, if the convolution spacing of the corrugated material 142 is too large, the computing system 400 determines adjustments that:

• • decrease the phase between a second pair of restrike rollers (that follow the restrike rollers 140) and the restrike rollers 140 (e.g., by momentarily decreasing the speed of the second restrike rollers) and rotating the second restrike rollers to put less pull into the convolutions;
  • move/shift the second restrike rollers toward the restrike rollers 140; and/or
  • raise the restrike rollers 140.

In some implementations, if the convolution spacing of corrugated material after a second pair of restrike rollers that follow the restrike rollers 140 is too small, the computing system 400 determines adjustments that:

• • lower the second restrike rollers; and/or
  • divert a section of the corrugated material to scrap.

In some implementations, if the convolution spacing of corrugated material after a second pair of restrike rollers that follow the restrike rollers 140 is too large, the computing system 400 determines adjustments that:

• • raise the second restrike rollers; and/or
  • divert a section of the corrugated material to scrap.

In some examples, the operations also include determining that a portion of the third corrugated material 142 has a convolution spacing that does not satisfy a pre-determined convolution spacing tolerance or range and, based on determining that the portion of the third corrugated material 142 has a convolution spacing that does not satisfy the pre-determined convolution spacing tolerance or range, diverting the portion of the third corrugated material 142 to scrap.

In some implementations, the operations also include obtaining a coil lot specification for the coiled material 112 and determining, based on the coil lot specification, obtaining one or more first settings of the one or more adjustable finger tensioners 130 and obtaining one or more second settings of the pair of adjustable restrike rollers 140. Here, the operations also include adjusting, based the one or more first settings, the one or more adjustable finger tensioners 130 and adjusting, based on the one or more second settings, the pair of adjustable restrike rollers 140.

In some examples, the adjustable rolling line 100 also includes a strobe light (not shown for clarity of illustration) configured to emit pulsed light at a frequency corresponding a pre-determined corrugation period to provide a visual indication of whether the convolution spacing of corrugated material equals the pre-determined corrugation period. Here, the visual indication may be used by an operator of the adjustable rolling line 100 to determine that the adjustable rolling line 100 is not producing corrugated material having the pre-determined corrugation period and scrap corrugated material, stop the adjustable rolling line 100, or make adjustments to the adjustable rolling line 100. In some examples, the visual indication is provided to a remotely located operator who can remotely control or adjust the adjustable rolling line 100.

FIG. 2 is a flowchart of an exemplary arrangement of operations for a method 200 for controlling the adjustable rolling line 100 for forming corrugated material for an aluminum heat exchanger for a vehicle. The operations may be performed by data processing hardware (e.g., the data processing hardware 410 of FIG. 4) based on executing instructions stored on memory hardware (e.g., the memory hardware 420 of FIG. 4). Many other ways of implementing the method 200 may be employed. For example, the order of execution of the operations may be changed, and/or one or more of the operations and/or interactions may be changed, eliminated, sub-divided, or combined. Additionally, the operations of FIG. 2 may be carried out sequentially and/or in parallel by, for example, separate processing threads, processors, devices, discrete logic, circuits, etc.

At operation 202, the method 200 includes setting initial settings of the adjustable rolling line 100. At operation 204, the method 200 includes reading current settings of the adjustable rolling line 100. At operation 206, the method 200 includes taking current convolution spacing measurements for corrugated material being formed by the adjustable rolling line 100. At operation 208, the method 200 includes, if the convolution spacings are within pre-determined convolution spacing ranges or tolerances, returning to operation 204. At operation 210, if the convolution spacings are not within pre-determined convolution spacing ranges or tolerances, the method 200 includes adjusting one or more settings of the adjustable rolling line 100 and/or diverting out-of-specification corrugated material to scrap.

FIG. 3 is a flowchart of another exemplary arrangement of operations for a method 300 for controlling the adjustable rolling line 100 for forming corrugated material for an aluminum heat exchanger for a vehicle. The operations may be performed by data processing hardware (e.g., the data processing hardware 410 of FIG. 4) based on executing instructions stored on memory hardware (e.g., the memory hardware 420 of FIG. 4). Many other ways of implementing the method 300 may be employed. For example, the order of execution of the operations may be changed, and/or one or more of the operations and/or interactions may be changed, eliminated, sub-divided, or combined. Additionally, the operations of FIG. 3 may be carried out sequentially and/or in parallel by, for example, separate processing threads, processors, devices, discrete logic, circuits, etc.

At operation 302, the method 300 includes obtaining, while an adjustable rolling line 100 is operating, a first measurement of a first convolution spacing of first corrugated material 132 formed from coiled material 112 by a pair of primary rollers 120 and one or more adjustable finger tensioners 130. At operation 304, the method 300 includes determining, based on the first measurement, one or more first adjustments to the one or more adjustable finger tensioners 130. At operation 306, the method 300 includes adjusting, based on the one or more first adjustments, the one or more adjustable finger tensioners 130.

At operation 308, the method 300 includes obtaining, while the adjustable rolling line 100 is operating, a second measurement of a second convolution spacing of second corrugated material 142 formed from the first corrugated material 132 by a pair of adjustable restrike rollers 140. At operation 310, the method 300 includes determining, based on the second measurement, one or more second adjustments to the pair of adjustable restrike rollers 140. At operation 312, the method 300 includes adjusting, based on the one or more second adjustments, the pair of adjustable restrike rollers 140.

FIG. 4 is schematic view of an example computing device 400 that may be used to implement the systems and methods described herein. The computing device 400 is intended to represent various forms of digital computers, such as controllers, laptops, desktops, workstations, servers, and other appropriate computers. The components shown here, their connections and relationships, and their functions, are meant to be exemplary only, and are not meant to limit implementations of the inventions described and/or claimed in this document.

The computing device 400 includes a processor 410 (i.e., data processing hardware), memory 420 (i.e., memory hardware), a storage device 430 (i.e., memory hardware), a high-speed interface/controller 440 connecting to the memory 420 and high-speed expansion ports 450, and a low speed interface/controller 460 connecting to a low speed bus 470 and a storage device 430. Each of the components 410, 420, 430, 440, 450, and 460, are interconnected using various busses, and may be mounted on a common motherboard or in other manners as appropriate. The processor 410 can process instructions for execution within the computing device 400, including instructions stored in the memory 420 or on the storage device 430 to display graphical information for a graphical user interface (GUI) on an external input/output device, such as display 480 coupled to high speed interface 440. In other implementations, multiple processors and/or multiple buses may be used, as appropriate, along with multiple memories and types of memory. Also, multiple computing devices 400 may be connected, with each device providing portions of the necessary operations (e.g., as a server bank, a group of blade servers, or a multi-processor system).

The memory 420 stores information non-transitorily within the computing device 400. The memory 420 may be a computer-readable medium, a volatile memory unit(s), or non-volatile memory unit(s). The non-transitory memory 420 may be physical devices used to store programs (e.g., sequences of instructions) or data (e.g., program state information) on a temporary or permanent basis for use by the computing device 400.

The storage device 430 is capable of providing mass storage for the computing device 400. In some implementations, the storage device 430 is a computer-readable medium. In various different implementations, the storage device 430 may be a floppy disk device, a hard disk device, an optical disk device, or a tape device, a flash memory or other similar solid state memory device, or an array of devices, including devices in a storage area network or other configurations. In additional implementations, a computer program product is tangibly embodied in an information carrier. The computer program product contains instructions that, when executed, perform one or more methods, such as those described above. The information carrier is a computer-or machine-readable medium, such as the memory 420, the storage device 430, or memory on processor 410.

The high speed controller 440 manages bandwidth-intensive operations for the computing device 400, while the low speed controller 460 manages lower bandwidth-intensive operations. Such allocation of duties is exemplary only. In some implementations, the high-speed controller 440 is coupled to the memory 420, the display 480 (e.g., through a graphics processor or accelerator), and to the high-speed expansion ports 450, which may accept various expansion cards (not shown). In some implementations, the low-speed controller 460 is coupled to the storage device 430 and a low-speed expansion port 490. The low-speed expansion port 490, which may include various communication ports (e.g., USB, Bluetooth, Ethernet, wireless Ethernet), may be coupled to one or more input/output devices, such as a keyboard, a pointing device, a scanner, or a networking device such as a switch or router, e.g., through a network adapter.

The computing device 400 may be implemented in a number of different forms, as shown in the figure. For example, it may be implemented as a standard server 400a or multiple times in a group of such servers 400a, as a laptop computer 400b, or as part of a rack server system 400c.

A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but, where applicable, are interchangeable and can be used in a selected configuration, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. An adjustable rolling line comprising:

a spool configured to hold coiled material;

a pair of primary rollers configured to form first corrugated material from the coiled material, the first corrugated material having a first convolution spacing;

one or more adjustable finger tensioners configured to form second corrugated material from the first corrugated material, the second corrugated material having a second convolution spacing;

a first measurement device configured to measure, while the adjustable rolling line is operating, a first measurement of the second convolution spacing;

a pair of adjustable restrike rollers configured to form third corrugated material from the second corrugated material for a heat exchanger for a vehicle, the third corrugated material having a third convolution spacing;

a second measurement device configured to measure, while the adjustable rolling line is operating, a second measurement of the third convolution spacing;

data processing hardware; and

memory hardware in communication with the data processing hardware and storing instructions that, when executed by the data processing hardware, cause the data processing hardware to perform operations comprising: determining, based on the measurement of the second convolution spacing, one or more first adjustments to the one or more adjustable finger tensioners; adjusting, based the one or more first adjustments, the one or more adjustable finger tensioners; determining, based on the measurement of the third convolution spacing, one or more second adjustments to the pair of adjustable restrike rollers; and adjusting, based the one or more second adjustments, the pair of adjustable restrike rollers.

2. The adjustable rolling line of claim 1, wherein the first measurement device comprises at least one of a laser, a camera, or a proximity sensor configured to measure distances to the second corrugated material, wherein the distances can be processed to determine, as the measurement of the second convolution spacing, distances between peaks of the second corrugated material.

3. The adjustable rolling line of claim 1, wherein the one or more first adjustments to the one or more adjustable finger tensioners comprise one or more of:

a position adjustment to a horizontal position of a first finger tensioner of the one or more adjustable finger tensioners;

a height adjustment to a vertical position of the first finger tensioner of the one or more adjustable finger tensioners; or

an angle adjustment to an angle of the first finger tensioner of the one or more adjustable finger tensioners.

4. The adjustable rolling line of claim 3, further comprising at least one adjustment component, wherein adjusting, based the one or more first adjustments, the one or more adjustable finger tensioners comprises controlling the at least one adjustment component to make the position adjustment, the height adjustment, and/or the angle adjustment.

5. The adjustable rolling line of claim 1, wherein the second measurement device comprises at least one of a laser, a camera, or a proximity sensor configured to measure distances to the third corrugated material, wherein the distances can be processed to determine, as the measurement of the third convolution spacing, distances between peaks of the third corrugated material.

6. The adjustable rolling line of claim 1, wherein the one or more second adjustments to the pair of adjustable restrike rollers comprises one or more of:

a position adjustment to a horizontal position of a first restrike roller of the pair of adjustable restrike rollers; or

a height adjustment to a vertical position of the first restrike roller of the pair of adjustable restrike rollers.

7. The adjustable rolling line of claim 6, further comprising at least one adjustment component, wherein adjusting, based the one or more second adjustments, the pair of adjustable restrike rollers comprises controlling the at least one adjustment component to make the position adjustment and/or the height adjustment.

8. The adjustable rolling line of claim 1, further comprising a strobe light configured to emit pulsed light at a frequency corresponding a pre-determined corrugation period to provide a visual indication of whether the second convolution spacing and/or the third convolution spacing equals the pre-determined corrugation period.

9. The adjustable rolling line of claim 1, wherein the operations further comprise:

determining that a portion of the third corrugated material has a fourth convolution spacing that does not satisfy a pre-determined convolution spacing tolerance; and

based on determining that the portion of the third corrugated material has the fourth convolution spacing that does not satisfy the pre-determined convolution spacing tolerance, diverting the portion of the third corrugated material to scrap.

10. The adjustable rolling line of claim 1, wherein the operations further comprise:

obtaining a coil lot specification for the coiled material;

determining, based on the coil lot specification, one or more first settings of the one or more adjustable finger tensioners;

adjusting, based on the one or more first settings, the one or more adjustable finger tensioners;

determining, based on the coil lot specification, one or more second settings of the pair of adjustable restrike rollers; and

adjusting, based on the one or more second settings, the pair of adjustable restrike rollers.

11. The adjustable rolling line of claim 1, wherein the operations further comprise displaying for an operator of the adjustable rolling line the first measurement and the second measurement.

12. The adjustable rolling line of claim 1, wherein:

determining, based on the measurement of the second convolution spacing, the one or more first adjustments to the one or more adjustable finger tensioners comprises determining the one or more first adjustments to maintain the second convolution spacing within a first pre-determined convolution spacing range; and

determining, based on the measurement of the third convolution spacing, the one or more second adjustments to the pair of adjustable restrike rollers comprises determining the one or more second adjustments to maintain the third convolution spacing within a second pre-determined convolution spacing range.

13. A method for controlling an adjustable rolling line, the method comprising:

obtaining, while the adjustable rolling line is operating, a first measurement of a first convolution spacing of first corrugated material formed from coiled material by a pair of primary rollers and one or more adjustable finger tensioners;

determining, based on the first measurement, one or more first adjustments to the one or more adjustable finger tensioners;

adjusting, based on the one or more first adjustments, the one or more adjustable finger tensioners;

obtaining, while the adjustable rolling line is operating, a second measurement of a second convolution spacing of second corrugated material formed from the first corrugated material by a pair of adjustable restrike rollers;

determining, based on the second measurement, one or more second adjustments to the pair of adjustable restrike rollers; and

adjusting, based on the one or more second adjustments, the pair of adjustable restrike rollers.

14. The method of claim 13, wherein the one or more first adjustments to the one or more adjustable finger tensioners comprise one or more of:

a position adjustment to a horizontal position of a first finger tensioner of the one or more adjustable finger tensioners;

a height adjustment to a vertical position of the first finger tensioner of the one or more adjustable finger tensioners; or

an angle adjustment to an angle of the first finger tensioner of the one or more adjustable finger tensioners.

15. The method of claim 13, wherein the one or more second adjustments to the pair of adjustable restrike rollers comprises one or more of:

a position adjustment to a horizontal position of a first restrike roller of the pair of adjustable restrike rollers; or

a height adjustment to a vertical position of the first restrike roller of the pair of adjustable restrike rollers.

16. The method of claim 13, further comprising:

determining that a portion of the second corrugated material has a third convolution spacing that does satisfy a pre-determined convolution spacing tolerance; and

based on determining that the portion of the second corrugated material has the third convolution spacing that does satisfy the pre-determined convolution spacing tolerance, diverting the portion of the second corrugated material to scrap.

17. The method of claim 13, further comprising determining, based on a coil lot specification, one or more first settings of the one or more adjustable finger tensioners;

adjusting, based on the one or more first settings, the one or more adjustable finger tensioners;

determining, based on the coil lot specification, one or more second settings of the pair of adjustable restrike rollers; and

adjusting, based on the one or more second settings, the pair of adjustable restrike rollers.

18. A system comprising:

data processing hardware; and

memory hardware in communication with the data processing hardware and storing instructions that, when executed by the data processing hardware, cause the data processing hardware to perform operations comprising: obtaining, while an adjustable rolling line is operating, a first measurement of a first convolution spacing of first corrugated material formed from coiled material by a pair of primary rollers and one or more adjustable finger tensioners; determining, based on the first measurement, one or more first adjustments to the one or more adjustable finger tensioners; adjusting, based on the one or more first adjustments, the one or more adjustable finger tensioners; obtaining, while the adjustable rolling line is operating, a second measurement of a second convolution spacing of second corrugated material formed from the first corrugated material by a pair of adjustable restrike rollers; determining, based on the second measurement, one or more second adjustments to the pair of adjustable restrike rollers; and adjusting, based on the one or more second adjustments, the pair of adjustable restrike rollers.

19. The system of claim 18, wherein the operations further comprise:

determining that a portion of the second corrugated material has a third convolution spacing that does not satisfy a pre-determined convolution spacing tolerance; and

based on determining that the portion of the second corrugated material has the third convolution spacing that does not satisfy the pre-determined convolution spacing tolerance, diverting the portion of the second corrugated material to scrap.

20. The system of claim 18, wherein the operations further comprise:

obtaining a coil lot specification for the coiled material;

determining, based on the coil lot specification, one or more first settings of the one or more adjustable finger tensioners;

adjusting, based the one or more first settings, the one or more adjustable finger tensioners;

determining, based on the coil lot specification, one or more second settings of the pair of adjustable restrike rollers; and

adjusting, based on the one or more second settings, the pair of adjustable restrike rollers.