Battery Pack Powered Roll Groover

This application claims the benefit of, and priority to, U.S. patent application Ser. No. 18/674,471, filed May 24, 2024, which claims the benefit of, and priority to, U.S. patent application Ser. No. 17/505,266, filed Oct. 19, 2021, which claims the benefit of, and priority to, U.S. Provisional Patent Application No. 63/093,577, filed on Oct. 19, 2020, and U.S. Provisional Patent Application No. 63/235,507, filed on Aug. 20, 2021, the entire content of each of which are hereby incorporated by reference.

In the pipe fitting industry, different methods are used to join two separate pieces of piping together. In one example, ends of the pipes are threaded and a threaded adapter is used to join the pipes together. An alternative to a threaded connection is a grooved connection. Specifically, a pipe is cut to the desired length and a groove is rolled onto an end of the pipe. A grooved adapter is then used to join the pipe to another pipe.

Grooved pipe connections are especially useful to join pipes carrying water and/or steam and to provide a water-tight seal between the pipes. A roll groover is used to produce a groove on the pipes. Roll groovers are typically mechanical devices that are placed on a pipe. A skilled user uses a crank mechanism to rotate the roll groover around the pipe to roll the groove onto the pipe. The crank mechanism involved manually rotating a crank by hand to rotate the roll groover.

Current roll groovers require skilled users to operate and take a large amount of time to complete one operation. Accordingly, there is a need for automated roll groovers that are simple to operate and reduce the operation time compared to current roll groovers.

Some embodiments provide a roll groover including a housing, an inner roller configured to be received in an inner circumference of a workpiece provided on the housing, and a groove roll configured to produce a groove on the workpiece provided on the housing. The roll groover includes a first motor to move the groove roll towards and away from the workpiece and a second motor to move the groove roll around a track and a circumference of the workpiece. The roll groover includes an electronic processor connected to the first motor and the second motor. The electronic processor is configured to operate the first motor to adjust the groove depth on the workpiece and the second motor to produce the groove on the workpiece.

Some embodiments provide a roll groover including a housing, an inner roller provided on the housing and configured to be received in an inner circumference of a workpiece, a groove roll provided on the housing and configured to produce a groove on the workpiece, one or more motors provided within the housing and configured to drive the groove roll, and an electronic processor electrically connected to the one or more motors. The electronic processor is configured to operate the one or more motors to perform a first operation of moving the groove roll in a radial direction. The first operation is performed to adjust a groove depth on the workpiece. The electronic processor is also configured to operate the one or more motors to perform a second operation of moving the groove roll in a circumferential direction. The second operation is performed to produce the groove on the workpiece.

In some aspects, the one or more motors include a first motor configured to drive the groove roll in the radial direction, and a second motor configured to drive the groove roll in the circumferential direction.

In some aspects, the roll groover also includes an inertial measurement unit configured to determine a position of the groove roll.

In some aspects, the electronic processor is also configured to control the one or more motors to move the groove roll around the workpiece while measuring a distance, and increase, using the one or more motors, groove depth in predetermined increments for each rotation of the groove roll by a first predetermined distance.

In some aspects, the roll groover also includes a battery pack configured to power the one or more motors.

In some aspects, the groove roll is provided on a circumferentially outer side of the inner roller.

In some aspects, the roll groover also includes a roll casing provided on the housing, wherein the groove roll is mounted to and moves with the roll casing. The roll casing with the groove roll moves around the track to produce the groove on the workpiece.

In some aspects, the roll groover also includes a jog trigger and a direction switch for selecting a direction of movement of the groove roll. The first operation is controlled using the jog trigger.

In some aspects, the roll groover also includes a run switch a direction switch for selecting a direction of movement of the groove roll. The second operation is controlled using the run switch.

In some aspects, the roll groover also includes one or more circuit boards provided within the housing and including electronic components of the roll groover. The one or more circuit boards includes a total surface area of less than 155 centimeters squared (cm2).

In some aspects, the electronic processor is also configured to detect an actuation of an arm/disarm button, control the one or more motors to move the groove roll toward the workpiece, detect, using one or more sensors, a current drawn by the one or more motors, determine whether the current exceeds an arm threshold, control the one or more motors to stop when the current exceeds the arm threshold, and provide an indication that the roll groover is armed.

In some aspects, the electronic processor is also configured to detect actuation of an arm/disarm button, control the one or more motors to move the groove roll away from the workpiece, determine whether the groove roll is at a home position, control the one or more motors to stop when the groove roll is at the home position, and provide an indication that the roll groover is disarmed.

In some aspects, the electronic processor is also configured to detect actuation of a jog trigger, control the one or more motors to move the groove roll toward the workpiece, and determine whether the jog trigger is still actuated. In response to the jog trigger continued to be activated, the electronic processor is configured to detect, using one or more sensors, a current drawn by the one or more motors, determine whether the current exceeds an arm threshold, control the one or more motors to stop when the current exceeds the arm threshold, and provide an indication that the roll groover is armed. In response to the jog trigger not being actuated, the electronic processor is configured to control the one or more motors to stop.

In some aspects, the electronic processor is also configured to detect actuation of a run button, determine, using an inertial measurement unit, an initial position of the groove roll, control the one or more motors to move the groove roll around the workpiece while measuring distance, determine whether the groove roll has rotated 360°, control the one or more motors to stop and record a measured distance when the groove roll has rotated 360°, determine a groove depth based on the measured distance.

In some aspects, the electronic processor is also configured to control the one or more motors to move the groove roll around the workpiece while measuring distance, determine whether the groove roll has traveled a first predetermined distance around a circumference of the workpiece, and determine whether the groove roll is below a second predetermined distance of a final depth when the groove roll has traveled the first predetermined distance. In response to the groove roll not being below the second predetermined distance of the final depth, the electronic processor is configured to control the one or more motors to increase groove depth by a predetermined increment. In response to the groove roll being below the second predetermined distance of the final depth, the electronic processor is configured to control the one or more motors to increase groove depth by a fractional increment, control the one or more motors to move the groove roll around the workpiece, determine whether the groove roll is at an initial position, and control the one or more motors to stop and indicate completion of operation when the groove roll is at the initial position.

In some aspects, the electronic processor is also configured to receive a selection of a single revolution mode, and control the one or more motors to complete a single revolution of the groove roll around the workpiece.

In some aspects, the roll groover also includes one or more light detection and ranging (LiDAR) sensors configured to detect objects in a vicinity of the roll groover. The electronic processor is further configured to detect that the roll groover is stationary, receive sensor data from the one or more LiDAR sensors, generate a base 3D point cloud based on the sensor data, continue operation of the roll groover, continuously scan the one or more LiDAR sensors to generate an updated 3D point cloud, compare the updated 3D point cloud to the base 3D point cloud, and determine whether an abnormal object is detected in the updated 3D point cloud. In response to detecting the abnormal object, the electronic processor is configured to determine whether the abnormal object is within a predetermined distance of the roll groover, and stop operation of the roll groover when the abnormal object is within the predetermined distance of the roll groover.

In some aspects, the inner roller includes a roller groove and the groove roll includes a roller projection corresponding to the roller groove. A force exerted by the roller projection on an outer circumference of the workpiece and an allowance provided by the roller groove on the inner circumference of the workpiece together produce the groove on the workpiece.

In some aspects, the groove roll is a replaceable die.

In some aspects, the electronic processor is also configured to receive a selection for measuring n amount of wear on the replaceable die, retrieve an initial distance an unworn replaceable die moves from a disarmed initial position to contact a fixed point, control the one or more motors to move the groove roll from the disarmed initial position to the fixed point in response to receiving the selection, measure a distance moved by the groove roll when the groove roll is moved from the disarmed initial position to contact the fixed point, determine whether the measured distance is greater than the initial distance, generate a first indication that the replaceable die is worn when the measured distance is greater than the initial distance, and generate a second indication that the replaceable die is unworn when the measured distance is not greater than the initial distance.

In some aspects, the groove roll and the inner roller form a replaceable die set.

In some aspects, the electronic processor is further configured to determine identification information of the replaceable die set.

In some aspects, the electronic processor is also configured to receive a selection for measuring workpiece dimension, retrieve an initial distance the groove roll moves from a disarmed initial position to contact the workpiece, control the one or more motors to move the groove roll from the disarmed initial position to contact the workpiece in response to receiving the selection, measure a distance moved by the groove roll when the groove roll is moved from the disarmed initial position to contact the workpiece, and determine the workpiece dimension based on a difference between the measured distance and the initial distance.

In some aspects, the electronic processor is also configured to compare the workpiece dimension to an expected thickness of the workpiece, and determine that the workpiece is already grooved when the workpiece dimension is smaller than the expected thickness.

In some aspects, the roll groover also includes a limit switch provided on the housing. The electronic processor is configured to detect, using the limit switch, a walk-off of the workpiece.

In some aspects, the electronic processor is also configured to detect, using an inertial measurement unit, movement of the groove roll around the workpiece, determine a profile of the workpiece based on the movement of the groove roll around the workpiece, compare the profile of the workpiece to a predetermined profile, and determine that the workpiece is oblong when the profile of the workpiece deviates from the predetermined profile.

In some aspects, the electronic processor is also configured to detect, using a sensor, an angle of the roll groover compared to the workpiece, and determine that the workpiece is a flared pipe when the detected angle deviates from a predetermined angle.

Some embodiments provide a roll groover including a housing, an inner roller provided on the housing and configured to be received in an inner circumference of a workpiece, a groove roll provided on the housing and configured to produce a groove on the workpiece, one or more motors provided within the housing and configured to drive the groove roll, an electronic processor electrically connected to the one or more motors. The electronic processor is configured to control the one or more motors to move the groove roll around the workpiece while measuring distance, determine whether the groove roll has traveled a first predetermined distance around a circumference of the workpiece, and determine whether the groove roll is below a second predetermined distance of a final depth when the groove roll has traveled the first predetermined distance. In response to the groove roll not being below the second predetermined distance of the final depth, the electronic processor is configured to control the one or more motors to increase groove depth by a predetermined increment. In response to the groove roll being below the second predetermined distance of the final depth, the electronic processor is configured to control the one or more motors to increase groove depth by a fractional increment, control the one or more motors to move the groove roll around the workpiece, determine whether the groove roll is at an initial position, and control the one or more motors to stop and indicate completion of operation when the groove roll is at the initial position.

Some embodiments provide a method of operating a roll groover including an inner roller configured to be received in an inner circumference of a workpiece and a groove roll configured to produce a groove on the workpiece. The method includes operating, using an electronic processor, one or more motors to perform a first operation of moving the groove roll in a radial direction. The first operation is performed to adjust a groove depth on the workpiece. The method also includes operating, using the electronic processor, the one or more motors to perform a second operation of moving the groove roll in a circumferential direction. The second operation is performed to produce the groove on the workpiece.

In some aspects, the method also includes determining, using an inertial measurement unit, a position of the groove roll.

In some aspects, the method also includes controlling the one or more motors to move the groove roll around the workpiece while measuring a distance, and increasing, using the one or more motors, groove depth in predetermined increments for each rotation of the groove roll by a first predetermined distance.

In some aspects, the method also includes providing, using a battery pack, power to the one or more motors.

In some aspects, the method also includes detecting an actuation of an arm/disarm button, controlling the one or more motors to move the groove roll toward the workpiece, detecting, using one or more sensors, a current drawn by the one or more motors, determining whether the current exceeds an arm threshold, controlling the one or more motors to stop when the current exceeds the arm threshold, and providing an indication that the roll groover is armed.

In some aspects, the method also includes detecting actuation of an arm/disarm button, controlling the one or more motors to move the groove roll away from the workpiece, determining whether the groove roll is at a home position, controlling the one or more motors to stop when the groove roll is at the home position, and providing an indication that the roll groover is disarmed.

In some aspects, the method also includes detecting actuation of a jog trigger, controlling the one or more motors to move the groove roll toward the workpiece, and determining whether the jog trigger is still actuated. In response to the jog trigger continued to be activated, the method includes detecting, using one or more sensors, a current drawn by the one or more motors, determining whether the current exceeds an arm threshold, controlling the one or more motors to stop when the current exceeds the arm threshold, and providing an indication that the roll groover is armed In response to the jog trigger not being actuated the method includes controlling the one or more motors to stop.

In some aspects, the method also includes detecting actuation of a run button, determining, using an inertial measurement unit, an initial position of the groove roll, controlling the one or more motors to move the groove roll around the workpiece while measuring distance, determining whether the groove roll has rotated 360°, controlling the one or more motors to stop and record a measured distance when the groove roll has rotated 360°, and determining a groove depth based on the measured distance.

In some aspects, the method also includes controlling the one or more motors to move the groove roll around the workpiece while measuring distance, determining whether the groove roll has traveled a first predetermined distance around a circumference of the workpiece, and determining whether the groove roll is below a second predetermined distance of a final depth when the groove roll has traveled the first predetermined distance. In response to the groove roll not being below the second predetermined distance of the final depth, the method includes controlling the one or more motors to increase groove depth by a predetermined increment. In response to the groove roll being below the second predetermined distance of the final depth, the method includes controlling the one or more motors to increase groove depth by a fractional increment, controlling the one or more motors to move the groove roll around the workpiece, determining whether the groove roll is at an initial position, and controlling the one or more motors to stop and indicate completion of operation when the groove roll is at the initial position.

In some aspects, the method also includes receiving a selection of a single revolution mode, and controlling the one or more motors to complete a single revolution of the groove roll around the workpiece.

In some aspects, the method also includes detecting that the roll groover is stationary, receiving sensor data from one or more light detection and ranging (LiDAR) sensors, generating a base 3D point cloud based on the sensor data, continuing operation of the roll groover, continuously scanning the one or more LiDAR sensors to generate an updated 3D point cloud, comparing the updated 3D point cloud to the base 3D point cloud, and determining whether an abnormal object is detected in the updated 3D point cloud. In response to detecting the abnormal object, the method includes determining whether the abnormal object is within a predetermined distance of the roll groover, and stopping operation of the roll groover when the abnormal object is within the predetermined distance of the roll groover.

In some aspects, the groove roll is a replaceable die and the method includes receiving a selection for measuring n amount of wear on the replaceable die, retrieving an initial distance an unworn replaceable die moves from a disarmed initial position to contact a fixed point, controlling the one or more motors to move the groove roll from the disarmed initial position to the fixed point in response to receiving the selection, measuring a distance moved by the groove roll when the groove roll is moved from the disarmed initial position to contact the fixed point, determining whether the measured distance is greater than the initial distance, generating a first indication that the replaceable die is worn when the measured distance is greater than the initial distance, and generating a second indication that the replaceable die is unworn when the measured distance is not greater than the initial distance.

In some aspects, the method also includes receiving a selection for measuring workpiece dimension, retrieving an initial distance the groove roll moves from a disarmed initial position to contact the workpiece, controlling the one or more motors to move the groove roll from the disarmed initial position to contact the workpiece in response to receiving the selection, measuring a distance moved by the groove roll when the groove roll is moved from the disarmed initial position to contact the workpiece, and determining the workpiece dimension based on a difference between the measured distance and the initial distance.

In some aspects, the method also includes comparing the workpiece dimension to an expected thickness of the workpiece, and determining that the workpiece is already grooved when the workpiece dimension is smaller than the expected thickness.

In some aspects, the method also includes detecting, using a limit switch, a walk-off of the workpiece.

In some aspects, the method also includes detecting, using an inertial measurement unit, movement of the groove roll around the workpiece, determining a profile of the workpiece based on the movement of the groove roll around the workpiece, comparing the profile of the workpiece to a predetermined profile, and determining that the workpiece is oblong when the profile of the workpiece deviates from the predetermined profile.

In some aspects, the method also includes detecting, using a sensor, an angle of the roll groover compared to the workpiece, and determining that the workpiece is a flared pipe when the detected angle deviates from a predetermined angle.