The precise control of straightening accuracy relies on a real-time, efficient detection system. Only by accurately identifying the bending position and deformation degree of the lamp post can the straightening machine apply targeted pressure, avoiding blind operations. Establishing a closed-loop control system of "Detection-Feedback-Adjustment" is the core technical approach to achieving high-precision straightening.
Precise positioning of bending defects is essential for pre-inspection. Prior to straightening, high-precision inspection equipment must conduct a comprehensive scan of the lamp post to determine critical parameters such as bending location and angle. Traditional manual inspection methods, which often yield significant errors, are now being progressively replaced by automated inspection systems. The mainstream solution employs a laser alignment system that uses multiple laser sensors to scan the lamp post axis in real time, achieving detection accuracy of 0.5 millimeters per meter and enabling precise identification of minor bending defects. This system can also integrate with visual inspection systems to perform full-surface imaging, eliminating detection errors caused by surface impurities or burrs. Upon completion of inspection, the system automatically generates a bending data report, providing accurate reference for subsequent straightening parameter settings.
Real-time feedback adjustment during pole straightening is crucial for precision control. In pole straightening operations, materials undergo elastic deformation and rebound. Relying solely on preset parameters may lead to precision deviations. Therefore, the straightening machine must be equipped with a real-time monitoring module to track the pole's deformation and pressure changes. For instance, displacement sensors installed at the support roller and pressure head collect real-time positional data of the pole, while pressure sensors provide instantaneous feedback on pressure application. This data is transmitted synchronously to the control system. Based on deviations between real-time data and preset standards, the control system automatically adjusts the pressure head position, pressure level, and straightening speed to achieve dynamic precision control. This closed-loop control mode effectively compensates for errors caused by material rebound, significantly improving straightening accuracy.
Post-rectification re-inspection ensures compliance with straightening standards. Upon completion of the straightening process, a secondary inspection must be conducted to verify if the straightening precision meets industry standards. This re-inspection can utilize the same laser profile instrument as the initial inspection, performing a full-length scan of the lamp post to check if the straightness tolerance complies with the industry standard of ≤1 mm/m. If deviations are detected, further fine-tuning based on re-inspection data is required until compliance is achieved. Simultaneously, both pre-and post-rectification inspection data should be documented and archived to establish a product quality traceability system, providing data support for subsequent process optimization.
