Description:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION
(Section 10 and Rule 13)

1. TITLE OF THE INVENTION:
SYSTEM AND METHOD FOR PROCESSING EXTRUTED TUBES IN AN EXTRUSION LINE
2. APPLICANTS:
Meril Life Sciences Pvt. Ltd., an Indian Company of the address, Survey No. 135/139 Bilakhia House, Muktanand Marg, Chala, Vapi-Gujarat 396191, India

3. The following specification particularly describes the invention and the manner in which it is to be performed:

FIELD OF INVENTION
[001] The present disclosure relates to the field of extrusion processes. More specifically, the present disclosure pertains to a system and a method for processing extruded tubes in an extrusion line.
BACKGROUND OF INVENTION
[002] Tubes are widely used across various industries, including construction, chemical processing, and medical applications. In each of these fields, tubes must conform to strict dimensional standards. Particularly, medical tubes are critical components in a wide range of healthcare applications, including intravenous (IV) lines, catheters, feeding tubes, and drainage systems. These tubes must adhere to stringent dimensional tolerances, particularly in terms of outer diameter (OD) and inner diameter (ID), to ensure safe and effective performance within the human body and compatibility with connectors, devices, and delivery systems. Even minor deviations in tube dimensions can compromise flow rates, create connection failures, or lead to patient safety risks.
[003] Given the high standards required in the medical field, continuous real-time monitoring of tube dimensions during the extrusion process is critical. Traditional manual inspection methods, such as caliper measurements and sample-based testing, are not only time-consuming but also susceptible to human error and limited sampling frequency. These limitations increase the likelihood of defective products passing through unnoticed, posing significant risks in clinical use.
[004] To address the limitations of manual inspection, laser gauge systems have been adopted to enable non-contact, high-precision measurement of medical tubing during extrusion. These systems typically involve a laser transmitter that projects a visible beam onto the surface of the extruded tube, while a sensor, typically, a Charge-Coupled Device (CCD) linear camera, captures the scattered light through a receiving lens. By analyzing the laser spot’s position and angle on the sensor and using the known geometry between the laser source and the camera, the system calculates the distance to the tube surface. This enables continuous, real-time monitoring of both outer and inner diameters throughout the extrusion process.
[005] Despite their measurement accuracy, existing systems implementing laser gauge system generally lack integrated mechanisms to isolate and remove only the defective segments of tubing. Consequently, either entire tube sections are unnecessarily discarded, or defective portions may proceed undetected. The absence of real-time cutting and rejection capability at the point of measurement compromises manufacturing efficiency and heightens the risk of non-compliant products entering the medical supply chain.
[006] Thus, there arises a need for a system that addresses the limitations and drawbacks of the conventional system.
SUMMARY OF INVENTION
[007] The present invention relates to a system for processing an extruded tube in an extrusion line. The system includes an inspection unit including one or more sensors configured to measure one or more attributes of the extruded tube, a cutting unit configured to cut the extruded tube into a plurality of segments, and a control unit coupled to the inspection unit and the cutting unit. The control unit includes one or more processors and a memory coupled to the one or more processors. The memory storing a set of storing instructions that, when executed by the one or more processors, cause the control unit to compare a measured value of each of the one or more attributes with a corresponding predefined value and based upon the comparison, the control unit perform one of: send a first cutting signal to the cutting unit, to actuate the cutting unit to cut a first segment of the extruded tube, the first segment having a first predefined length or send a second cutting signal to the cutting unit, to actuate the cutting unit to cut a second segment of the extruded tube, the second segment having a second predefined length different than the first predefined length.
[008] The foregoing features and other features as well as the advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures.
BRIEF DESCRIPTION OF DRAWINGS
[009] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the apportioned drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale.
[0010] Fig. 1 depicts a schematic view of an exemplary system 100 for processing an extruded tube 150 in an extrusion line, in accordance with an embodiment of the present disclosure.
[0011] Fig. 2 depicts a schematic view of a processing unit 110 of the system 100, in an accordance with an embodiment of the present disclosure.
[0012] Fig. 2A depicts a schematic view of a pulling unit 220 of the processing unit 110, in an accordance with an embodiment of the present disclosure.
[0013] Fig. 2B depicts a schematic view of an inspection unit 210 of the processing unit 110, in an accordance with an embodiment of the present disclosure.
[0014] Fig. 2C1-2C2 depict various views of a cutting unit 230 of the processing unit 110, in an accordance with an embodiment of the present disclosure.
[0015] Fig. 3A depicts a schematic view of a sorting unit 120 of the system 100, in an accordance with an embodiment of the present disclosure.
[0016] Fig. 3B depicts an enlarged schematic view of a portion of the sorting unit 120, in an accordance with an embodiment of the present disclosure.
[0017] Fig. 3C depicts a block diagram of an ejecting mechanism 160 of the system 100, in an accordance with an embodiment of the present disclosure.
[0018] Fig. 4 depicts a flowchart of a method 400 for processing extruded tubes 150 in an extrusion line using the system 100, in an accordance with an embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0019] Prior to describing the invention in detail, definitions of certain words or phrases used throughout this patent document will be defined: the terms "include" and "comprise", as well as derivatives thereof, mean inclusion without limitation; the term "or" is inclusive, meaning and/or; the phrases "coupled with" and "associated therewith", as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have a property of, or the like; Definitions of certain words and phrases are provided throughout this patent document, and those of ordinary skill in the art will understand that such definitions apply in many, if not most, instances to prior as well as future uses of such defined words and phrases.
[0020] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment, but mean “one or more but not all embodiments” unless expressly specified otherwise. The terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise.
[0021] Although the operations of exemplary embodiments of the disclosed method may be described in a particular, sequential order for convenient presentation, it should be understood that the disclosed embodiments can encompass an order of operations other than the particular, sequential order disclosed. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Further, descriptions and disclosures provided in association with one particular embodiment are not limited to that embodiment, and may be applied to any embodiment disclosed herein. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed system, method, and apparatus can be used in combination with other systems, methods, and apparatuses.
[0022] Furthermore, the described features, advantages, and characteristics of the embodiments may be combined in any suitable manner. One skilled in the relevant art will recognize that the embodiments may be practiced without one or more of the specific features or advantages of a particular embodiment. In other instances, additional features and advantages may be recognized in certain embodiments that may not be present in all embodiments. These features and advantages of the embodiments will become more fully apparent from the following description and apportioned claims, or may be learned by the practice of embodiments as set forth hereinafter.
[0023] The present disclosure relates to a system and a method for processing extruded tubes in an extrusion line, particularly for use in the medical industry. Extruded tubes are critical components in a wide range of healthcare applications, including intravenous (IV) lines, catheters, feeding tubes, and drainage systems. In an embodiment, the system includes an inspection unit, a cutting unit, a sorting unit, and a control unit that operate in coordination. The inspection unit is configured to inspect the extruded tube. In an aspect, the inspection unit is configured to measure one or more attributes of the extruded tube. The one or more attributes include at least one outer diameter, inner diameter, wall thickness, geometric smoothness, and the presence of defects on the surface. The cutting unit is configured to cut the extruded tube into segments of different predefined lengths, specifically, a first segment having a first predefined length and a second segment having a second predefined length. The sorting unit is configured to sort the segments of the extruded tube into the respective collection bins. The control unit is coupled to the inspection unit, the cutting unit, and the sorting unit. the control unit is configured to control the cutting unit and the sorting unit. The control unit is configured to compare the measured one or more values of the one or more attributes, such as dimensional or surface attributes of the extruded tube, and compare these against corresponding predefined values. The predefined data includes reference standards and threshold values defining an acceptable tolerance range for conformance. Based on the comparison, the control unit determines whether a segment of the extruded tube is conforming (i.e., within the acceptable tolerance range) or non-conforming (i.e., outside the acceptable tolerance range).
[0024] Based on the identification, the control unit generates a first cutting signal when the measured values indicate conformance and a second cutting signal when the measured values indicate non-conformance. The first and second cutting signals correspond to the cutting of the extruded tube into a first segment (conforming segment) and the second segment (non-conforming segment), respectively. Each cutting signal may include timing information to ensure precise actuation of the cutting unit. Following the cutting operation, the control unit generates one or more sorting signals to actuate the ejecting mechanism(s) of the sorting unit for directing the first and second segments into respective collection bins (e.g., a first bin for conforming segments and a second bin for non-conforming segments). The configuration ensures consistent adherence to quality standards, enables automated quality-based segregation, and supports a streamlined extrusion process.
[0025] Referring to the figures, Fig. 1 depicts a schematic view of a system 100 for processing an extruded tube 150 in an extrusion line, in accordance with an embodiment of the present disclosure. The system 100 is integrated within the extrusion line and is configured to process the extruded tube 150. In an embodiment, the system 100 is configured to inspect, cut, and sort the extruded tube 150. The system 100 includes a processing unit 110, a sorting unit 120, and a control unit 130. The processing unit 110 and the sorting unit 120 are disposed sequentially along the extruded tube flow direction of the extrusion line, such that the extruded tube 150 passes through the processing unit 110 before reaching the sorting unit 120. In an embodiment, the processing unit 110 is configured to inspect, cut, and pull the extruded tube 150. The control unit 130 is coupled to the processing unit 110 and the sorting unit 120 to coordinate and manage their respective functions in real-time.
[0026] In an embodiment, the units of the extrusion line, including a extruder (not shown), a cooling unit (not shown), the processing unit 110, and the sorting unit 120, are arranged sequentially in-line along a central axis corresponding to the extruded tube 150 flow direction. The processing unit 110 is positioned downstream of the cooling unit and is adapted to receive the extruded tube 150 directly from the cooling unit for inspection and cutting. The sorting unit 120 is positioned further downstream of the processing unit 110 and configured to receive the tube segments from the processing unit 110 and sort them into designated collection bins. In an embodiment, the sorting unit 120 is coupled and aligned with an output end of the processing unit 110 to enable direct and seamless transfer of the extruded tube segments from the processing unit 110 to the sorting unit 120, without intermediate handling or repositioning. This linear and modular arrangement minimizes mechanical transitions, reduces handling delays, and mitigates the risk of misalignment or damage during transfer. Additionally, the in-line configuration supports straightforward integration into existing extrusion lines and contributes to enhanced processing efficiency and quality control. In an embodiment, the processing unit 110 is mounted on a first base frame 102 and the sorting unit 120 is mounted on a second base frame 104, thereby enabling modular installation and structural stability.
[0027] Fig. 2 depicts a schematic view of the processing unit 110 of the system 100, in an accordance with an embodiment of the present disclosure. In an embodiment, the processing unit 110 includes an inspection unit 210, a pulling unit 220, and a cutting unit 230. The inspection unit 210 is positioned downstream of the cooling unit, where the extruded tube 150 undergoes crystallization and solidification after being extruded from the extruder. The positioning of the inspection unit 210 immediately after the cooling phase allows real-time assessment of the extruded tube 150 before further processing, enabling timely identification of defects and reducing waste. The inspection unit 210 is configured to detect or measure one or more attributes of the extruded tube 150. In an embodiment, the one or more attributes include outer diameter, inner diameter, wall thickness, roundness or ovality, length, height, scratches, bubbles, burn mark, contamination or discoloration, burrs, rough edges, presence of a hole, perforation, etc., or combinations thereof. In an example implementation, the one or more attributes include an outer diameter and an inner diameter.
[0028] Fig. 2A depicts a schematic view of the pulling unit 220, in an accordance with an embodiment of the present disclosure. The pulling unit 220 is mounted on the first base frame 102. The pulling unit 220 is configured to pull the extruded tube 150 from the cooling unit of the extrusion line. The pulling unit 220 ensures continuous and stable movement of the extruded tube 150 along the extrusion line, thereby maintaining consistent tension and dimensional integrity during downstream processing. In an embodiment, the pulling unit 220 includes a plurality of rollers 222 arranged in opposing pairs to grip the extruded tube 150 from both the top and bottom sides. Each roller 222 is mounted on a rotatable shaft 224 and is driven by a motor (not shown), such as an electric or servo motor, to apply a synchronized pulling force. In an embodiment, the rollers 222 are made of rubberized or elastomer-coated material to provide adequate friction while preventing damage to the tube surface.
[0029] Optionally, the pulling unit 220 further includes a pressure adjustment mechanism, such as a spring-loaded or pneumatic actuator system, to control the contact force between the rollers 222 and the extruded tube 150, accommodating variations in diameter and hardness of the extruded tube 150. Additionally, the assembly of the rollers 222 is supported on a rigid frame 226 with guides or rails to maintain alignment between the corresponding rollers 222, which reduces vibration during operation.
[0030] Optionally, the pulling unit 220 includes one or more motion and position sensors (not shown) configured to monitor the speed of the rollers 222 and alignment of the extruded tube 150. These sensors transmit the monitored data to the control unit 130. Based on the monitored data, the control unit 130 regulates the flow of the extruded tube 150 and adjusts the extruded tube 150 alignment to prevent wear and dislocation.
[0031] The pulling unit 220 is operationally coupled to the control unit 130 and is configured to engage with and draw the extruded tube 150 along the extrusion line at a controlled speed and tension. The control unit 130 regulates the operation of the pulling unit 220 to ensure consistent and stable advancement of the extruded tube 150 during inspection, cutting, and sorting processes. In an embodiment, the control unit 130 receives feedback signals from sensors associated with the pulling unit 220, such as motion sensors or a position sensor, to monitor the pulling speed and the tensile force applied to the extruded tube 150. The coordination between the pulling unit 220 and the control unit 130 enables precise synchronization across the extrusion line, thereby minimizing dimensional variation and ensuring quality control of the tube segments.
[0032] Fig. 2B depicts a schematic view of the inspection unit 210, in an accordance with an embodiment of the present disclosure. The inspection unit 210 is positioned between the cooling unit and the pulling unit 220. In an embodiment, the inspection unit 210 is mounted on the first base frame 102 along the central axis of the extrusion line. In an embodiment, the inspection unit 210 includes a ring 214, which encircles the extruded tube 150, and a base 212 coupled to the ring 214. The base 212 is mounted on the first base frame 102 and provides stability and support. The inspection unit 210 includes one or more sensors 216 arranged around the periphery of the ring 214 to perform non-contact measurement and detection of the extruded tube 150.
[0033] The one or more sensors 216 are configured to detect one or more attributes of the extruded tube 150. The one or more sensors 216 may include, but are not limited to, a laser gauge, an optical sensor, a vision sensor, an infrared sensor, an ultrasonic sensor, a capacitive sensor, an inductive sensor, and a contact sensor, etc. In an embodiment, the one or more sensors 216 include at least one laser gauge configured to detect dimensional attributes of the extruded tube 150, including outer diameter, inner diameter, wall thickness, roundness or ovality, length, and height, etc. In an embodiment, the one or more sensors include at least one optical sensor configured to detect surface attributes such as, scratches, bubbles, burn marks, contamination or discoloration, burrs, rough edges, presence of holes, and perforations, etc. In an example implementation, the one or more sensors include a laser gauge configured to measure the outer diameter and the inner diameter of the extruded tube 150.
[0034] Fig. 2C1 – 2C2 depict various views of the cutting unit 230, in an accordance with an embodiment of the present disclosure. The cutting unit 230 is positioned downstream of the pulling unit 220 in the extrusion line. The cutting unit 230 is configured to cut the extruded tube 150 into a plurality of segments. In an embodiment, the cutting unit 230 includes a cutting blade 234 (hereinafter, blade 234). Examples of the blade 234 include, without limitation, a rotary blade, a guillotine blade, or a saw blade. The type of cutting blade 234 is selected according to the material properties and wall thickness of the extruded tube 150. In one embodiment, the blade 234 is a rotary blade. In an embodiment (depicted in Fig. 2C2), the cutting unit 230 comprises a housing 236 within which the blade 234 is mounted on a pivoting arm 232. The pivoting arm 232 is operatively coupled to a drive assembly 238. The drive assembly 238 may include, but is not limited to, a motor, pneumatic, or hydraulic actuator configured to actuate the pivoting arm 232. This enables controlled movement of the blade 234 to perform a clean and precise cut of the extruded tube 150 against a supporting member 239. The housing 236 encloses the cutting components to ensure operational safety and minimize external contamination. The supporting member 239 is positioned on the housing 236 and includes a first member 239a and a second member 239b. The first member 239a is coupled to the housing 236, and the second member 239b is coupled to the first member 239a such that the coupling between the first member 239a and the second member 239b forms a cavity 239c that is configured to accommodate the blade 234 during the cutting against a supporting surface of the supporting member 239.
[0035] In an embodiment, the system 100 includes a speed sensor configured to measure the speed of the extruded tube 150 as the extruded tube 150 passes between the inspection unit 210, the pulling unit 220 and the cutting unit 230. In an embodiment, the speed sensor is capable of non-contact measurement of the speed of the extruded tube 150. The speed sensor may include an optical or laser-based sensor. The speed sensor is positioned at a desired location between the inspection unit 210 and the cutting unit 230. The speed sensor is coupled to the control unit 130 and is configured to send, in real-time, the measured speed to the control unit 130. These measurements provide real-time feedback to the control unit 130, which uses the data to accurately trigger the cutting unit 230 at predefined lengths as explained later. This ensures consistent segmentation of the extruded tube 150, regardless of extrusion speed variations, and facilitates synchronized cutting operations for both conforming and non-conforming segments.
[0036] Fig. 3A and 3B depict a schematic view and an enlarged schematic view of the sorting unit 120, in accordance with an embodiment of the present disclosure. The sorting unit 120 is positioned downstream of the cutting unit 230 in the extrusion line and is configured to receive and sort the tube segments of the extruded tube 150. In an embodiment, the sorting unit 120 includes a plurality of collection bins 302 positioned on the second base frame 104. The plurality of collection bins 302 is configured to receive the tube segments. In an embodiment, the sorting unit 120 includes a first collection bin 302a for storing the first (i.e., conforming) segments and a second collection bin 302b for storing the second (i.e., non-conforming). The sorting unit 120 is configured to sort the tube segments into the respective collection bins 302.
[0037] The sorting unit 120 includes a conveyor 122 configured to transport the tube segments from the cutting unit 230 toward the collection bins. The control unit tracks the position of each of the first and second segments on the conveyor 122. The control unit 130 then generates a corresponding sorting signal to actuate one or more ejection mechanisms 160 of the sorting unit 120, thereby directing the first and second segments into the first collection bin 302a and the second collection bin 302b, respectively.
[0038] The conveyor 122 may be a belt-type, chain-type, or mechanical, and is designed to maintain a continuous flow of tube segments. In an embodiment, the conveyor 122 includes a belt-type mechanism including a belt 123, a plurality of rollers 124, and a motor 125. The belt 123 is looped around the plurality of rollers 124, which guide and support the movement of the belt 123 along a defined path. The rollers 124 may be configured with low-friction bearings to reduce resistance and increase efficiency. The surface of the belt 123 may be composed of an anti-slip or textured material to ensure secure transport of tube segments of varying diameters and lengths.
[0039] The motor 125 is mounted on the second base frame 104 and is operationally coupled to at least one of the rollers 124 via a chain or belt mechanism 126 (hereinafter referred to as the chain mechanism 126). The chain mechanism 126 transmits rotational power from the motor 125 to the at least one roller 124, enabling synchronized and consistent belt movement.
[0040] Optionally, the conveyor 122 may include adjustable side guides or containment rails 127 positioned along the belt’s edges to ensure the proper alignment and prevent lateral movement of the tube segments during transit.
[0041] In an embodiment, the sorting unit 120 includes at least one ejecting mechanism configured to selectively direct the first and second segments into the appropriate collection bins 302. The ejecting mechanism includes a pneumatic actuator, a mechanical pusher, an electromagnetic ejector, a servo-driven flap, a rotary actuator, a conveyor diverter mechanism, a robotic arm, or combinations thereof.
[0042] In an embodiment, the ejecting mechanism is implemented as an ejection mechanism 160 (shown in Fig. 3C) that utilizes targeted bursts of compressed air to redirect the tube segments along the conveyor 122. The ejection mechanism 160 comprises a plurality of air nozzles 161, a flow control valve 162, and an air compressor 163. The plurality of air nozzles 161 is mounted along one or more sides of the conveyor 122 and operatively connected to the flow control valve 162, which in turn is connected to the air compressor 163. The air compressor 163 is mounted on the second base frame 104 (as depicted in Fig. 1), and the flow control valve 162 is positioned on the first base frame 102 (as depicted in Fig. 1). The air compressor 163 and the flow control valve 162 are operationally coupled to the control unit 130. The control unit 130 activates the air compressor 163 to supply the air to each air nozzle 161 via the flow control valve 162. The control unit 130 is configured to momentarily open the flow control valve 162 to release a short, high-pressure burst of air through the corresponding air nozzle 161. In an embodiment, the air nozzles 161 are positioned and oriented such that the air burst displaces the first and second segments laterally off their normal path into the first collection bin 302a and the second collection bin 302b, respectively. The ejection mechanism 160 enables rapid, contactless sorting and is particularly suitable for high-speed extrusion processes. In an embodiment, the flow control valve 162 includes a sinusoidal valve, a check valve, a pressure relief valve, a needle valve, a solenoid-operated valve, or any other suitable valve mechanism configured to regulate, restrict, or permit fluid flow within the system based on operational requirements.
[0044] The control unit 130 is operationally coupled to the inspection unit 210, the pulling unit 220, the cutting unit 230, and the sorting unit 120. The control unit 130 is configured to coordinate and control the operation of the pulling unit 220, the cutting unit 230, and the sorting unit 120 based on real-time data received from the inspection unit 210. In particular, the control unit 130 regulates the pulling speed of the pulling unit 220, actuates the cutting unit 230 to perform cutting operations at precise moments, and activates the sorting unit 120 to direct tube segments into appropriate collection bins, thereby ensuring synchronized and accurate functioning of the overall system.
[0045] In an embodiment, the control unit 130 includes one or more processors 132 (hereinafter, the processor 132) and a memory 131 coupled to the processor 132. The memory 131 may include various types of storage, such as read-only memory (ROM), random-access memory (RAM), flash memory, hard disk drives, solid state drives, or non-transitory storage. In an embodiment, the memory 131 is configured to store the one or more predefined data, which is used by the control unit 130 to evaluate the quality of the extruded tube 150. The predefined data includes one or more predefined values and allowable tolerance ranges corresponding to the attributes of the extruded tube 150. Specifically, the predefined value for a given attribute represents a reference or desired value for that attribute. For example, in an extrusion process for fabricating the extruded tube 150 having an outer diameter of 10 mm, the predefined value corresponding to the outer diameter is 10 mm. Further, the allowable tolerance range for an attribute represents an acceptable manufacturing tolerance for that attribute and is defined based upon the use of the extruded tube 150 and the desired precision. Considering the above example, the allowable tolerance range for the outer diameter may, for example, be set as ±0.05 mm. Additionally, the memory 131 is configured to store historical dimension range data, representing previously recorded measurement ranges of the extruded tube 150. Such data is used for quality tracking, process optimization, and trend analysis. In an embodiment, the processor 132 may include a microcontroller, microprocessor, application-specific integrated circuit (ASIC), or any other suitable computing device. The memory 131 is configured to store a set of instructions that when executed by the processor 132, cause the processor 132 to perform various functions of the control unit 130 as described herein.
[0046] The control unit 130 is configured to receive real-time measured attributes of the extruded tube 150 from the inspection unit 210. Upon receipt of the measured attributes, the control unit 130 is configured to compare the measured value of each of the one or more attributes with a corresponding predefined value, as described above. In an embodiment, based upon the comparison, the control unit 130 is configured to generate and send a first cutting signal to the cutting unit 230 to actuate the cutting unit 230 to cut a first segment of the extruded tube 150 having a first predefined length or generate and send a second cutting signal to the cutting unit 230 to actuate the cutting unit 230 to cut a second segment of the extruded tube 150 having a second predefined length. The second predefined length is different from the first predefined length. The first predefined length corresponds to the desired length of the extruded tube 150 and is chosen based upon the use of the extruded tube 150. For example, when the extrusion line where the system 100 is deployed is designed to manufacture the extruded tube 150 of length 1 m, the first predefined length is set as 1 m. In this example, the second predefined length may, for example, be set at 50 cm. The use of different first and second predefined lengths is selected to facilitate visual distinction, ease of manual inspection, or segregation for reprocessing or disposal. In an embodiment, the second predefined length is smaller than the first predefined length. Since the second segments are discarded (due to being non-conforming), setting the second predefined length smaller than the first predefined length reduces wastage of material. According to one embodiment, the control unit 130 computes a deviation between the measured value of the one or more attributes and the corresponding predefined values. For example, the deviation between the measured value of an attribute and the corresponding predefined value is equal to an absolute difference between the measured value of the attribute and the corresponding predefined value. The control unit 130 further compares the computed deviation with a corresponding predefined allowable tolerance range. In an embodiment, when the deviation falls, or is, within the allowable tolerance range, the control unit 130 determines that the extruded tube 150 is conforming and sends the first cutting signal to the cutting unit 230. The cutting unit 230 cuts the first segment of the extruded tube 150 having the first predefined length, in response to receiving the first cutting signal. For example, the drive assembly 238 receives the first cutting signal and actuates the blade 234 (e.g., rotates the blade 234 for one rotation) to cut the extruded tube 150. As used herein, “lying within the allowable tolerance range” refers to any deviation of the measured attribute that falls within the thresholds that define the allowable tolerance range, thereby indicating the conforming tube segment.
[0047] For example, the predefined acceptable outer diameter of the extruded tube 150 is 2.00 mm, with an allowable tolerance range of ±0.05 mm. The inspection unit 210 measures the outer diameter of a segment of the extruded tube 150 and transmits a measured value of 2.03 mm to the control unit 130. The control unit 130 calculates the deviation between the measured value (2.03 mm) and the predefined value (2.00 mm) as 0.03 mm. Since this deviation lies within the allowable tolerance range of ±0.05 mm, the control unit 130 determines that the tube segment is conforming. Accordingly, the control unit 130 generates and sends the first cutting signal to the cutting unit 230, which in turn actuates the drive assembly 238 to rotate the blade 234 once and cut the extruded tube 150 to the first predefined length of 1 meter.
[0048] Conversely, when the deviation lies outside the allowable tolerance range, the control unit 130 determines that the extruded tube is non-conforming and sends the second cutting signal to the cutting unit 230 to cut the second segment of the extruded tube 150, having the second predefined length. This enables selective cutting of tube segments based on assessment for further downstream sorting and processing. For example, the predefined acceptable outer diameter of the extruded tube 150 is 2.00 mm, with an allowable tolerance range of ±0.05 mm. The inspection unit 210 measures the outer diameter of a segment of the extruded tube 150 and transmits a measured value of 2.07 mm to the control unit 130. The control unit 130 calculates the deviation between the measured value (2.07 mm) and the predefined value (2.00 mm) as 0.07 mm. Since this deviation falls outside the allowable tolerance range of ±0.05 mm, the control unit 130 determines that the tube segment is non-conforming. Accordingly, the control unit 130 generate and send the second cutting signal to the cutting unit 230, which in turn actuates the drive assembly 238 to rotate the blade 234 once and cut the extruded tube 150 to the first predefined length of 1 meter which would then cut the tube to the second predefined length of 50 cm.
[0049] Each of the first and second cutting signals includes timing information. The cutting unit 230 is configured to cut the first segment or the second segment according to the timing information. In an embodiment, the timing information dictates the precise moment at which the cutting unit 230 is actuated to perform a cutting operation. The timing information is determined based on real-time data received from the inspection unit 210 and the speed of the extruded tube 150, as regulated by the pulling unit 220. The control unit 130 receives data related to the speed or pulling rate of the extruded tube 150 from the speed sensor or from the pulling unit 220. The control unit 130 analyzes this data, along with the known distance between the inspection unit 210 and the cutting unit 230, to compute the optimal cutting timing for actuating the cutting unit 230. This ensures that the cutting unit 230 executes the cut at the correct location on the moving extruded tube 150 to obtain the first and second segments of accurate length. For example, when the pulling speed is 100 mm/sec, and the distance between the inspection unit 210 and the cutting unit 230 is 1 meter, the control unit 130 calculates a cutting delay of 10 seconds from the time of measurement. If the measured segment is conforming, the control unit 130 waits 10 seconds before sending a first cutting signal to obtain the conforming segment as the first segment. Conversely, when the segment is identified as non-conforming, the control unit 130 sends the second cutting signal after the same calculated delay of 5 seconds. Still, the resulting segment is classified as a rejected or non-conforming segment. In an embodiment, the distance between the inspection unit 210 and the cutting unit 230 is greater than or equal to the first predefined length. This allows the control unit 130 to verify that the entire first predefined length of the extruded tube 150 is conforming before cutting the extruded tube 150 into the first segment.
[0050] Accordingly, when the control unit 130 sends the first cutting signal corresponding to an acceptable or conforming tube segment (the first segment), or the second cutting signal corresponding to a defective or non-conforming tube segment (the second segment), the associated timing information enables the cutting unit 230 to operate with high positional precision.
[0051] Further, the control unit 130 is configured to generate and transmit at least one sorting signal to the sorting unit 120 to sort the first and second segments. Specifically, in an embodiment, the control unit 130 is configured to send a first sorting signal to the sorting unit 120 to actuate the ejecting mechanism for directing the first segment (i.e., a compliant or conforming segment) into the first collection bin302a. Conversely, the control unit 130 is configured to send a second sorting signal to actuate the ejecting mechanism to direct the second segment (i.e., the non-compliant, non-conforming or defective segment) into the second collection bin 302b. The first and second sorting signals may also include timing or positional information synchronized with the speed of the conveyor 122 and the movement of the first and second segments to ensure accurate and coordinated ejection of the respective segments into the appropriate collection bins. The control unit 130 obtains the conveyor speed information from a sensor or encoder operatively coupled to the conveyor 122, allowing the control unit 130 to track the segment position in real time. This cooperative control between the cutting and sorting stages enables automated classification and segregation of tube segments, enhancing quality assurance and operational efficiency within the extrusion line.
[0052] In one embodiment, the sorting operation is carried out manually by an operator who visually distinguishes the segment types based on their lengths (i.e., based upon the first and second predefined lengths) and places them into the designated collection bins 302. In a preferred embodiment, the sorting is automated using the ejecting mechanisms actuated based on the sorting signals generated by the control unit 130 as described herein. Automated sorting improves process efficiency, reduces human error, and enables consistent classification and segregation of tube segments based on quality assessment.
[0053] In an embodiment, the system 100 includes a human-machine interface (HMI) system 140 (shown in Fig. 1) mounted on the first base frame 102. The human-machine interface (HMI) system 140 is positioned at a desired location to ensure easy accessibility and visibility for the operator. The human-machine interface (HMI) system 140 is coupled to the control unit 130 and is configured to receive the predefined values for one or more attributes and/or corresponding allowable tolerance range. The human-machine interface (HMI) system 140 is equipped with an input interface that enables the operator to feed or modify the predefined data of the extruded tube 150, such as the predefined values, corresponding allowable tolerance ranges for the attributes, quality thresholds, or sorting criteria. In an embodiment, the human-machine interface (HMI) system 140 includes a display configured to visually present real-time and historical value related to the extruded tube 150. Such values include, but are not limited to, measured values of the attributes, corresponding predefined values, corresponding allowable tolerance ranges, inspection outcomes, and processing status. In an embodiment, the HMI system 140 includes at least one input device enabling the user to enter the predefined data and interact with the system 100. The at least one input device includes, for example, a keyboard, one or more control buttons, a touch pad, a mouse, a touch screen, or combinations thereof. In various embodiment, the human-machine interface (HMI) system 140 include, without limitation, a touchscreen panel, a programmable logic controller (PLC)-based graphical interface, a graphical LCD or LED panel, or an integrated control panel featuring either physical buttons and/or a touchscreen interface. In an embodiment, the HMI system 140 includes a display providing both display and input capabilities. The human-machine interface (HMI) system 140 provides both display and input functionalities, thereby enabling the operator to configure and manage system performance and interact with it for configuration and control. The predefined values and/or the allowable tolerance ranges are user-configurable through the HMI interface provided by the HMI system 140, facilitating operational flexibility and customization based on specific extrusion requirements.
[0054] Fig. 4 illustrates a flowchart of a method 400 for processing the extruded tube 150 in the extrusion line using the system 100, in accordance with an embodiment of the present disclosure.
[0055] At step 401, the one or more sensors 216 of the inspection unit 210 measure, in real-time, one or more attributes of the extruded tube 150 as the extruded tube exits after crystallization. The one or more attributes include dimensional attributes and/or surface attributes such as outer diameter, inner diameter, wall thickness, geometric conformity, smoothness, the presence of defects on the surface, and color consistency of the extruded tube 150.
[0056] At step 402, the control unit 130 receives, in real-time, measured values of the attributes from the one or more sensors 216 of the inspection unit 210. This allows for real-time data acquisition during continuous tube extrusion.
[0057] At step 403, the control unit 130 compares, in real-time, the measured value of each of the one or more attributes with the corresponding predefined value. In an embodiment, the comparison includes computing a deviation between the measured value and the corresponding predefined value of each attribute and comparing the deviation for each attribute with a corresponding predefined allowable tolerance range.
[0058] At step 404, based on the comparison, the control unit 130 generates a first cutting signal or a second cutting signal. According to an embodiment, when the deviation for the one or more attributes is within the respective predefined allowable tolerance range, the control unit 130 generates the first cutting signal. Similarly, in an embodiment, when the deviation for one or more attributes is outside the corresponding predefined allowable tolerance range, the control unit 130 generates the second cutting signal. As explained earlier, the deviation being within the allowable tolerance range indicates that the extruded tube 150 is conforming and conversely, the deviation being outside the allowable tolerance range indicates the extruded tube 150 is non-conforming or defective. In an embodiment, the control unit 130 generates the first cutting signal when the deviation for all attributes is within the allowable tolerance range and generates the second cutting signal when the deviation for any of the attributes is outside the allowable tolerance range.
[0059] At step 405, the control unit 130 sends the first cutting signal or the second cutting signal to the cutting unit 230, to actuate the cutting unit 230 to cut the extruded tube 150 into the first segment or the second segment, respectively. As explained earlier, the first segment has the first predefined length and the second segment has the second predefined length, wherein the second predefined length is different than the first predefined length.
[0060] Optionally, the control unit 130 generates and sends a first sorting signal or a second sorting signal to the sorting unit 120 to sort the first segment and the second segment into the first collection bin 302a and the second collection bin 302b, respectively. In an embodiment, the control unit 130 sends the first and second sorting signals to the ejection mechanism 160. For example, in response to the first or the second sorting signal, a corresponding solenoid valve is actuated and a high-pressure burst of air is output through a respective air nozzle 161 to direct the first or second segment into the respective collection bin 320.
[0061] The system offers substantial advantages in improving the efficiency, accuracy, and quality control of extruded tube production. The system ensures real-time detection and segregation of non-conforming products. This automation significantly reduces reliance on manual inspection, leading to faster production cycles and higher throughput. The system enhances precision by continuously evaluating key tube attributes, such as dimensional accuracy, surface quality, and geometric conformity, against predefined standards, thereby ensuring consistent product quality. Automated cutting and sorting minimize material waste because defective segments are identified and separated early in the process, preventing downstream processing of non-compliant material. This targeted removal approach conserves raw material usage, reduces unnecessary reprocessing, and limits the production of scrap. Furthermore, automated cutting and sorting optimize resource utilization and improve overall operational efficiency. The system also supports scalable deployment and can be easily adapted to various product specifications, making it a versatile and robust solution for modern extrusion manufacturing lines.
[0062] The scope of the invention is only limited by the appended patent claims. More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the teachings of the present invention is/are used.
, Claims:WE CLAIM
1. A system (100) for processing an extruded tube (150) in an extrusion line, the system (100) comprising:
a. an inspection unit (210) comprising one or more sensors (216) configured to measure one or more attributes of the extruded tube (150);
b. a cutting unit (230) configured to cut the extruded tube (150) into a plurality of segments;
c. a control unit (130) coupled to the inspection unit (210) and the cutting unit (230), the control unit (130) comprising one or more processors (132) and a memory (131) storing instructions that, when executed by the one or more processors (132), cause the control unit (130) to:
i. compare a measured value of each of the one or more attributes with a corresponding predefined value; and
ii. based upon the comparison, perform one of:
• send a first cutting signal to the cutting unit (230), to actuate the cutting unit (230) to cut a first segment of the extruded tube (150), the first segment having a first predefined length; or
• send a second cutting signal to the cutting unit (230), to actuate the cutting unit (230) to cut a second segment of the extruded tube (150), the second segment having a second predefined length different than the first predefined length.
2. The system (100) as claimed in claim 1, wherein the control unit (130) is configured to:
a. compute a deviation between the measured value of the one or more attributes and the corresponding predefined values;
b. compare the deviation for the one or more attributes with a corresponding predefined allowable tolerance range;
c. send the first cutting signal when the deviation is within the allowable tolerance range; and
d. send the second cutting signal when the deviation exceeds the allowable tolerance range.
3. The system (100) as claimed in claim 2, wherein each of the first and second cutting signals comprises timing information, wherein the cutting unit (230) is configured to cut the first segment or the second segment according to the timing information.
4. The system (100) as claimed in claim 1, wherein the one or more sensors (216) comprises at least one of: a laser gauge, an optical sensor, a vision sensor, an infrared sensor, an ultrasonic sensor, a capacitive sensor, an inductive sensor, a contact sensor, or a combination thereof.
5. The system (100) as claimed in claim 4, wherein the one or more sensors (216) comprises a laser gauge.
6. The system (100) as claimed in claim 1, wherein the one or more attributes comprises at least one of: an outer diameter, an inner diameter, a wall thickness, roundness or ovality, puncture, smoothness, bubbles, or scratch.
7. The system (100) as claimed in claim 1, wherein the one or more attributes comprise an outer diameter and an inner diameter.
8. The system (100) as claimed in claim 1, wherein the system (100) comprises a sorting unit (120) coupled to the control unit (130) and comprising at least one ejecting mechanism, wherein the control unit (130) is configured to:
a. send a first sorting signal to actuate the at least one ejection mechanism (160) to eject the first segment into a first collection bin (302a); and
b. send a second sorting signal to actuate the at least one ejection mechanism (160) to eject the second segment into a second collection bin (302b).
9. The system (100) as claimed in claim 8, wherein the at least one ejection mechanism (160) comprises a pneumatic actuator, a mechanical pusher, an electromagnetic ejector, a servo-driven flap, a rotary actuator, a conveyor diverter mechanism, a robotic arm or a combination of thereof.
10. The system (100) as claimed in claim 1, wherein the system (100) comprises an HMI system (140) coupled to the control unit (130) and configured to receive the predefined values for the one or more attributes and/or corresponding allowable tolerance range.
11. The system (100) as claimed in claim 1, wherein the second predefined length is smaller than the first predefined length.
12. A method (400) for processing an extruded tube (150) in an extrusion line, the method (400) comprising:
a. measuring, by an inspection unit (210), one or more attributes of the extruded tube (150);
b. receiving, by a control unit (130), a measured value of the one or more attributes;
c. comparing, by the control unit (130), the measured value of each of the one or more attributes with a corresponding predefined allowable tolerance range;
d. generating, by the control unit (130), a first cutting signal or a second cutting signal based on the comparison; and
e. sending, by the control unit (130), the first cutting signal or the second cutting signal to a cutting unit (230), to actuate the cutting unit (230) to cut the extruded tube (150) into a first segment or a second segment, respectively, the first segment having a first predefined length and the second segment having a second predefined length, the second predefined length being different than the first predefined length.
13. The method (400) as claimed in claim 12, wherein comparing the measured value comprises:
a. computing a deviation between the measured value of the one or more attributes and the corresponding predefined value; and
b. comparing the deviation for the one or more attributes with a corresponding predefined allowable tolerance range;
c. wherein the step of generating the first cutting signal or the second cutting signal comprises:
i. generating the first cutting signal when the deviation is within the corresponding allowable tolerance range; and
ii. generating the second cutting signal when the deviation exceeds the corresponding allowable tolerance range.
14. The method (400) as claimed in claim 12, wherein the one or more attributes comprise at least one of: an outer diameter, an inner diameter, a wall thickness, roundness or ovality, puncture, smoothness, bubbles, or scratch.
15. The method (400) as claimed in claim 12, wherein the method (400) comprises:
a. sending, by the control unit (130), a first sorting signal to at least one ejection mechanism (160) of a sorting unit (120) to actuate the at least one ejection mechanism (160) to eject the first segment into a first collection bin (302a); and
b. sending, by the control unit (130), a second sorting signal to the at least one ejection mechanism (160) to actuate the at least one ejection mechanism (160) to eject the second segment into a second collection bin (302b).