In sectors such as aerospace, automotive, and shipbuilding, piping systems perform critical functions—including fuel transport, signal transmission, and cable protection—across various subsystems like engines, braking systems, and air conditioning. Consequently, the reliability of these pipes directly impacts the performance and service life of the entire system.
During the manufacturing process, the bending parameters and procedures for CNC tube benders must be adapted to the specific characteristics of the tubing material. Therefore, trial production and calibration are required; adjustments based on inspection results ensure that the finished components meet tolerance specifications.
Currently, the industry relies primarily on traditional mechanical gauges (template-based methods), supplemented by contact-based inspection tools such as Coordinate Measuring Machines (CMMs) and articulated arms. These measurement processes are time-consuming, fail to quantify deviations, offer poor traceability, and make full-batch inspection difficult. Measurement complexity is further heightened for specialized components—such as irregularly shaped, elongated, or flexible tubes—and the resulting data offers limited utility for optimizing the bending process itself.
TUBE QUALIFY
One-Click, Fully Automated Measurement and Inspection
The XTOP3D TUBE QUALIFY 3D bent-tube measurement system is specifically designed to overcome the unique challenges associated with measuring complex bent-tube assemblies. Users simply place the bent tube into the measurement zone—without restrictions on material or orientation—and initiate the process with a single click. The system rapidly and accurately captures precise 3D data, enabling the simultaneous measurement of multiple tubes with high speed and precision.
The system utilizes TUBE QUALIFY 3D tube bending software to compare a rapidly reconstructed 3D model of the actual tube against the theoretical design model. This enables rapid inspection of bending parameters (XYZ or YBC), allows for the visualization of out-of-tolerance locations on the 3D model, and facilitates quantitative correction based on detected deviations. Furthermore, the software converts these deviations into bending correction values, thereby reducing the number of adjustments required during prototype trials, improving machine setup efficiency, and ensuring consistent quality in mass production.
The XTOP3D TUBE QUALIFY 3D tube measurement system, paired with specialized tube-bending software, meets the measurement requirements for a wide range of tubular components—including flexible hoses, free-form bent tubes, variable-diameter tubes, branched tubes, composite tubes, and adapters. With one-click operation, the system captures key tube-bending parameters such as bend point coordinates (XYZ), YBC data, and sleeve tolerances; this streamlines workflows, reduces operator skill requirements, and enhances inspection efficiency.
3D Deviation Display for Bent Tubes
Locations where the bent tube deviates from the 3D model specifications can be visualized; this enables quantitative correction based on deviation detection.
Pipe Alignment and Stock Allowance Inspection
For pipes with uncut stock allowance, the allowance is calculated based on quality inspection standards—rather than process data—during the best-fit analysis. This ensures that the main body of the pipe remains compliant with quality standards after the allowance is trimmed.
Flexible Hose Inspection
Utilizes non-contact visual measurement technology for bent tubes, making it suitable for inspecting easily deformable hoses; capable of automatically segmenting and combining measurements based on the minimum rigid section length of the tube.
Measurement of free-form bent tubes
Measurement of variable-diameter pipes
Independent Process Data
When the bending angle of a pipe is 180°, the straight segments at both ends of the bend are parallel, making it impossible to determine the bend point by finding their intersection. To address this, a splitting method is employed, converting the single large-angle bend into multiple smaller-angle bends for inspection.
Measurement of Composite Tee Fittings
Measuring the position and angle of the tee fitting using a linear adapter.
Measurement of composite piping with ball-end and threaded connections
Measuring the composite piping assembly using a positioning and orientation adapter
Measurement of Flanged and Flared Composite Pipes
Supports inspection of flanges, flared ends, ball ends, right-angle ends, and threaded ends.
Composite Pipe Measurement
Supports inspection of branch pipes and bifurcated pipes.
Multi-tube synchronous measurement
The TUBE QUALIFY 3D tube inspection software communicates directly with tube bending machines, selectively outputting parameters such as real-time processing corrections and springback compensation. It logs cumulative correction data and generates adjustments based on specific parameters and material properties, thereby minimizing machine setup and calibration time. The TUBE QUALIFY system can also be integrated with robotic arms, loading/unloading racks, and host control systems to achieve highly efficient, automated tube inspection.
XTOP3D has accumulated nearly two years of technical expertise in the field of tube measurement. Its TUBE QUALIFY 3D optical tube measurement solutions have been adopted by manufacturers in the automotive and aerospace sectors, as well as by various other tube production enterprises. Furthermore, the company has successfully expanded internationally, deploying its systems across multiple BRICS nations and securing contracts as a designated supplier for tube inspection equipment.
