SBIR Phase I: IPPM: IN-LINE PIERCING PROCESS MONITORING FOR SEAMLESS TUBE MANUFACTURING

SBIR 第一阶段：IPPM：无缝管材制造的在线穿孔过程监控

• 批准号: 0944614
• 负责人: Tzyy-Shuh Chang
• 金额: $ 15万
• 依托单位: OG TECHNOLOGIES, INC
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2010
• 资助国家: 美国
• 起止时间: 2010-01-01 至 2010-06-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0944614&HistoricalAwards=false
• 关键词: SBIR; Phase; IPPM; LINE; PIERCING

This Small Business Innovation Research (SBIR) Phase I project seeks to verify the feasibility of an imaging based monitoring system for the piercing process used in the manufacturing of seamless steel tubes. Piercing is the core process of seamless tubes manufacturing, the process that puts a hole in a steel bar without drilling chips. Seamless tubes are crucial materials in many critical applications ranging from energy, chemical, automotive, aerospace to infrastructure. Piercing, if not done correctly, could cause tube quality issues. The proposed innovation consists of a set of imaging sensors for measuring the part vibrations in the piercing process. The vibration data will be used to derive the piercing conditions for critical failure modes through advanced mathematical analysis. This project is expected to validate the new approach on selected tubes, forming the basis for the commercialization of a new piercing monitoring system. This project will be carried out by a team consisting of industry-academia collaboration. Tests in a tube mill are planned for performance verification. The broader impact/commercial potential of this project is very significant. This project presents an approach with soft as well as hard sensors to control a highly stochastic and non-linear process. When commercialized, it will improve seamless steel tubing manufacturing by reducing mill downtime, fewer set-up pieces, and tightened tolerances. This project also reduces the pollution emissions and costly energy consumption associated with remanufacturing or reworking out-of-tolerance products. Industry-wide adoption across the seamless tube and pipe industry could yield drastic reductions in waste byproducts and would produce a cost savings of $250 million per year. Scientifically, the project could have an impact on the adoption of emerging high dimensional data analysis techniques. The project carries strong educational implication due to the close working relationship with the academia. Social impact is also expected with this project, by improving energy preservation and environmental protection. The estimated benefits include energy savings of 3 terawatt-hours and reduction of 300,000 tons of carbon-equivalent emission and 260,000 tons of toxic waste per year. Beyond the piercing process, the success of the project will also provide generic modeling and analysis tools for systems with complex information.

这个小企业创新研究（SBIR）第一阶段项目旨在验证一种基于成像的监控系统在无缝钢管制造中穿孔过程中的可行性。穿孔是无缝管制造的核心工序，在钢筋上穿孔而不钻孔。无缝管是从能源、化工、汽车、航空航天到基础设施等许多关键应用领域的关键材料。穿孔，如果做得不正确，可能会导致管的质量问题。提出的创新包括一套成像传感器，用于测量零件在穿孔过程中的振动。振动数据将通过先进的数学分析推导出关键失效模式的穿孔条件。该项目预计将在选定的管材上验证新方法，为新型穿孔监测系统的商业化奠定基础。该项目将由一个产学研合作的团队进行。计划在管材厂进行性能验证试验。这个项目的广泛影响/商业潜力是非常显著的。该项目提出了一种采用软传感器和硬传感器来控制高度随机和非线性过程的方法。当商业化时，它将通过减少工厂停机时间、减少安装件和收紧公差来改善无缝钢管的制造。该项目还减少了与再制造或返工超公差产品相关的污染排放和昂贵的能源消耗。在无缝管和管道行业的广泛应用可以大大减少废物副产品，每年可节省2.5亿美元的成本。在科学上，该项目可能对采用新兴的高维数据分析技术产生影响。由于与学术界的密切合作关系，该项目具有很强的教育意义。通过改善节能和环境保护，该项目也有望产生社会影响。预计效益包括每年节省3太瓦时的能源，减少30万吨碳当量排放和26万吨有毒废物。除了穿孔过程之外，该项目的成功还将为具有复杂信息的系统提供通用建模和分析工具。