Compact orbital welder

Abstract

An orbital welder includes a first module, a second module coupled to the first module at a pivot, a weldhead assembly configured to perform a welding process on a circular workpiece, and a motor disposed in one of the first module or the second module and configured to drive movement of the weldhead assembly relative to the circular workpiece. The first module and the second module are configured to rotate relative to one another about the pivot, and the first module and the second module cooperatively define a space configured to receive the circular workpiece.

Description

COMPACT ORBITAL WELDERGOVERNMENT LICENSE RIGHTS

[0001] This invention was made with the support of the U.S. Government and the U.S. Government has certain rights in the invention.CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

[0002] This patent application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 652,829, entitled “COMPACT ORBITAL WELDER,” filed May 29, 2024, and U.S. Provisional Patent Application No. 63 / 680,202, entitled “COMPACT ORBITAL WELDER,” filed August 7, 2024, each of which hereby incorporated by reference in its entirety for all purposes.TECHNICAL FIELD

[0003] The present disclosure is directed toward a welding system and, in particular, a compact orbital welder configured to weld around a workpiece, such as a pipe.BACKGROUND

[0004] A welding process is used to join two components (e.g., parts of a workpiece) to one another. For example, the welding process may melt a filler material, such as metal, at an interface between the two components. The filler material then solidifies to secure the components together. An orbital welder (e.g., an orbital welding device, orbital welding apparatus, etc.) performs a welding process around a workpiece, such as a pipe or tube. As an example, the orbital welder may secure to and travel around the workpiece. During its travel, a guide of the orbital welder may direct filler material toward the workpiece and a torch of the orbital welder melts the filler material onto the workpiece. It is desirable for an orbital welder to be able to weld differently sized workpieces. However, it may be difficult for the orbital welder to weld workpieces of certain sizes, such as workpieces with smaller diameters.SUMMARY

[0005] Techniques related to performing an orbital welding process are presented herein. These techniques may be embodied as one or more orbital welders.

[0006] In accordance with at least one embodiment, the present application is directed to an orbital welder. The orbital welder includes a first module, a second module coupled to thefirst module at a pivot, a weldhead assembly configured to perform a welding process on a circular workpiece, and a motor disposed in one of the first module or the second module and configured to drive movement of the weldhead assembly relative to the circular workpiece. The first module and the second module are configured to rotate relative to one another about the pivot, and the first module and the second module cooperatively define a space configured to receive the circular workpiece.

[0007] In accordance with at least another embodiment, the present application is directed to an orbital welder. The orbital welder includes a first module housing, a second module housing pivotably coupled to the first module housing, a weldhead assembly configured to perform a welding process on a circular workpiece, a linkage coupling the weldhead assembly to the second module housing, and a motor disposed in the second module housing. The motor is configured to move the linkage to drive movement of the weldhead assembly relative to the second module and relative to the circular workpiece.

[0008] In accordance with at least one other embodiment, the present application is directed to an orbital welder. The orbital welder includes a first module, a second module coupled to the first module, a weldhead assembly coupled to the second module and configured to perform a welding process on a circular workpiece, a first motor configured to actuate a linkage to drive movement of the weldhead assembly relative to the second module to move the weldhead assembly toward and away from the circular workpiece, and a second motor configured to actuate the linkage to drive movement of the weldhead assembly relative to the second module to move the weldhead assembly relative to the second module along the rotational axis. The first module and the second module are configured to rotate relative to one another about a rotational axis.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] To complete the description and in order to provide for a better understanding of the present disclosure, a set of drawings is provided. The drawings form an integral part of the description and illustrate an embodiment of the present disclosure, which should not be interpreted as restricting the scope of the disclosure, but just as an example of how the disclosure can be carried out. The drawings comprise the following figures:

[0010] FIG. 1 is a front perspective view of a welding system, according to an embodiment of the present disclosure.

[0011] FIG. 2 is a front perspective view of an orbital welder coupled to a workpiece, according to an embodiment of the present disclosure.

[0012] FIG. 3 is a rear perspective view of the orbital welder of FIG. 2 coupled to the workpiece.

[0013] FIG. 4 is an exploded view of the orbital welder and the workpiece of FIG. 2.

[0014] FIG. 5 is a side perspective view of the orbital welder of FIG. 2 coupled to the workpiece with a portion of the orbital welder illustrated transparently.

[0015] FIG. 6 is another side perspective view of the orbital welder of FIG. 2 coupled to the workpiece with a portion of the orbital welder illustrated transparently.

[0016] FIG. 7 is a perspective view of an embodiment of a weldhead assembly of an orbital welder, according to an embodiment of the present disclosure.

[0017] FIG. 8 is a bottom view of the weldhead assembly of FIG. 7.

[0018] FIG. 9A is a bottom perspective view of another weldhead assembly, according to an embodiment of the present disclosure.

[0019] FIG. 9B is a bottom perspective view of yet another weldhead assembly, according to an embodiment of the present disclosure.

[0020] FIG. 10 is a front view of an embodiment of the orbital welder of FIG. 2 coupled to the workpiece.

[0021] FIG. 11 is a perspective view of the orbital welder of FIG. 2 coupled to another workpiece, according to an embodiment of the present disclosure.

[0022] FIG. 12 is a front view of the orbital welder of FIG. 2 coupled to the other workpiece.

[0023] FIG. 13 is a front view of the orbital welder of FIG. 2 coupled to yet another workpiece.

[0024] FIG. 14 is a method for securing an orbital welder to a workpiece, according to an embodiment of the present disclosure.

[0025] FIG. 15 is a method for operating an orbital welder to perform a welding process on a workpiece, according to an embodiment of the present disclosure.

[0026] FIG. 16 is a hardware block diagram of a computing device that may execute the techniques presented herein.

[0027] Like reference numerals have been used to identify like elements throughout this disclosure.DETAILED DESCRIPTION

[0028] The following description is not to be taken in a limiting sense but is given solely for the purpose of describing the broad principles of the disclosure. Embodiments of the disclosure will be described by way of example, with reference to the above-mentioned drawings showing elements and results according to the present disclosure.

[0029] Generally, the present application is directed to an orbital welder configured to perform a welding process on a workpiece, such as a circular workpiece (e.g., a pipe, a tube). The orbital welder includes a first module (e.g., a first section) and a second module (e.g., a second section) rotatably coupled to one another. The first module and the second module cooperatively define a space configured to receive the workpiece. The orbital welder also includes a guide assembly disposed around the workpiece. A wheel disposed in the first module or the second module engages the guide assembly, and rotation of the wheel drives movement of the first module and the second module about the guide assembly.

[0030] Moreover, rotation of the first module and the second module relative to one another adjusts a size of the space in which the workpiece may be positioned. Thus, the first module and the second module may move to suitably accommodate a particularly sized workpiece. By way of example, the orbital welder may be configured to couple to differently sized workpieces, such as pipes or tubes of different diameters, by moving the first module and the second module toward or away from one another. As such, a single orbital welder may perform a welding process for different workpieces, allowing an end user to avoid purchasing multiple orbital welders and / or avoiding having to manufacture dedicated orbital welders for differently sized workpieces. Consequently, a cost and / or complexity associated with performing a welding process for differently sized workpieces is reduced. Still further, in certain embodiments, the first module and the second module are arranged such that the space defined by the first module and the second module is open to avoid blocking insertion of the workpiece into the space. Such an arrangement of the first module and the second module may adjust a size of the space to receive a wide range of workpiece sizes, including relatively small workpieces (e.g., workpieces having a small diameter).

[0031] The orbital welder further includes a weldhead assembly coupled to one of the first module or the second module. The weldhead assembly includes a guide configured to direct filler material toward the workpiece, as well as a torch configured to melt the filler material. By way of example, the torch may be configured to generate an arc between the torch and the workpiece to melt the filler material. Thus, as the first module and the second module moveabout the ring assembly, the guide and the torch cooperatively provide the filler material onto and around the workpiece to perform the welding process. The weldhead assembly also includes an imaging device, such as a camera, that is oriented to face the torch. The imaging device is configured to capture image data associated with operation of the torch, which, for example, may be representative of a quality' of a weld being produced by melting filler material. The image data captured by the imaging device may be used to adjust operation of the orbital welder, such as positioning of the weldhead assembly (e.g.. of the torch) relative to the workpiece to perform the welding process more desirably.

[0032] In some embodiments, separate motors (e.g., motion servos) are configured to drive movement of the weldhead assembly relative to the workpiece to enable the weldhead assembly to perform the welding process. For example, a first motor may be configured to rotate the wheel to drive movement of the first module and the second module, as well as the weldhead assembly, about the workpiece. A second motor may be configured to drive movement of the weldhead assembly toward and away from the workpiece to adjust the arc generated between the torch and the workpiece for melting the filler material. A third motor may be configured to drive movement of the weldhead assembly along an axis (e.g., a longitudinal axis) of extension of the workpiece. Movement of the weldhead assembly along the axis of extension of the workpiece enables the torch and the guide to fully fill a weld seam and / or increase deposition rates at a certain section of a weld seam. As such, each motor is dedicated to providing a different type of movement of the weldhead assembly relative to the workpiece, and the respective operations of each motor can acutely control movement of the weldhead assembly.

[0033] Moreover, the motors are disposed within the modules to reduce a total physical footprint of the orbital welder. In other words, positioning the motors within the modules instead of, for example, external to and separate from the modules, reduces a total amount of space (e.g., a volume) occupied by the orbital welder. In turn, this improves ease of transportation, operation, and / or placement of the orbital welder (e.g., within an area of relatively low clearance), while providing sufficient movement of the orbital welder to produce a desirable weld seam (e.g., by moving the orbital welder desirably in an oscillatory motion). By way of example, the wheel configured to engage the ring assembly may be disposed in the first module, and a link may couple the weldhead assembly to the second module. Thus, the first motor is disposed in the first module to enable the first motor to drive movement of the wheel. Meanwhile, the second motor and the third motor may be disposed in the second module to enable the second motor and the third motor to drive movement of the link of theweldhead assembly. Such an arrangement of the motors enables the orbital welder to move desirably to complete a welding operation while limiting an amount of space occupied by the orbital welder.

[0034] With the preceding in mind, FIG. 1 is a perspective view of an embodiment of a welding system 2. The welding system 2 includes a power supply 11, wire feeders 14, and a cooling component / cabinet 30 disposed on a cart 12. The welding system 2 also includes welders 16 (e.g.. welding torches). In the depicted embodiment, the welders 16, which may also referred to as torches, welding devices, welding torches, etc., are connected to the wire feeders 14 via torch cables 18. Also, in the depicted embodiment, one of the welders 16 is depicted as a MIG welder and one of the welders 16 is depicted as an orbital welder. This is not intended to be limiting in any manner and is merely one example arrangement for welding system 2. Moreover, the term ‘'welder” used herein is not intended to be limiting in any manner and is used to broadly describe cutting and welding torches. Thus, despite the arrangements depicted in the Figures, a “welder” may comprise a metal inert gas (MIG) torch, a tungsten inert gas (TIG) torch, a submerged arc welding (SAW) torch, a plasma cutting torch, a plasma spray torch, a plasma welding torch, a plasma gouging torch, any combination thereof, or any other variation of a welding or cutting apparatus.

[0035] During operation of the depicted welding system 2, the wire feeders 14 provide a wire to at least one of welders 16. The power supply 11 charges the wires to strike an arc between the electrically charged wire and a metal workpiece to melt the wire and fuse the wire onto the metal workpiece. To effectuate this, each torch 16 includes a trigger, and a user can actuate the trigger to cause one of the welders 16 to electrically charge the wire and / or feed the wire toward the metal work piece. But, to reiterate, while the welders 16 utilize a fed wire in the illustrated embodiment, in additional or alternative embodiments, torches implementing the techniques presented herein need not utilize a wire. For example, one or both of the welders 16 can be tungsten inert gas (TIG) torches that strike an arc (e.g., via an electrically charged electrode) and transfer this arc to a separate component (e.g., a filler rod) to weld a metal work piece via the arc. As another example, the one or both of welders 16 could be plasma torches. In such examples, the wire feeders 14 and / or the cooling component 30 might not be included in the welding system 2.

[0036] The wielding system 2 also includes connector assemblies 200, 202 to fluidly, electrically, and operatively interconnect components of the welding system 2. In the depicted embodiment, the connector assemblies 200, 202 are disposed on a side panel of the components, but other embodiments may include any number of ports in or separate fromconnector assemblies, which may be similar or dissimilar to those depicted, in any desirable location(s). That said, in the depicted embodiments, one or more cables 17 engage the connector assemblies 200 and 202 to electrically and / or fluidly connect the power supply 11 to the wire feeders 14, the cooling cabinet 30 to the wire feeders 14, and / or the power supply 11 to the cooling cabinet 30. As an example, the power supply 11 is configured to supply current and / or control signals to the wire feeders 14 and / or to the cooling cabinet 30.

[0037] The cables 17 may also electrically couple to the power supply 11, the wire feeders 14, and / or the cooling cabinet 30 via sockets 210 of the connector assembly 200. Thus, the process current and / or control signals may be conducted from the power supply 11 via the connector assembly 200 and the cables 17 to the wire feeders 14 and / or to the cooling cabinet 30. Still further, in at least some instances, the cables 17 fluidly couple to the cooling cabinet 30 and / or the power supply 1 1 via sockets 218 (e.g., sockets 218A, 218B) of the connector assembly 202. Thus, cooling fluid may flow from the cooling cabinet 30, through the cables 17 via the connector assembly 202, and to the wire feeders 14 and / or to the power supply 11. The cooling fluid may also flow from the wire feeder 14 and / or from the power supply 11 to the connector assembly 202 via the cables 17. To this end, the connector assembly 202 may include supply sockets for supplying a flow cooling fluid and return sockets for receiving a return flow of the cooling fluid.

[0038] With the wire feeders 14 connected to the pow er supply 11 and the cooling cabinet 30, the wire feeders 14 can provide the process current, the cooling fluid, the weld wire, and / or the control signals to respective welders 16 via the torch cables 18 to perform a welding operation. However, the depicted embodiments in FIG. 1 are merely example arc process components. In other embodiments, the sockets 210 and 218 could be configured to receive any ty pe of cable (e.g., a cable dedicated to transferring / feeding w elding wire, control signals, cooling fluid, gas, and / or process current).

[0039] In certain embodiments, a welding system (e.g., the welding system 2) can operate autonomously. That is, the welding system can automatically feed filler material (e.g., a wire) to be welded onto the workpiece, position a w elding apparatus to generate an arc betw een the welding apparatus and the workpiece to weld the filler material onto the workpiece, and move the welding apparatus relative to a workpiece to weld about the workpiece. Components, e.g., computing components including one or more processors, to effectuate automated welding or cutting may be disposed in any component of welding system 2 or may be included in a component not shown (e.g., a controller that may be used with or added to welding system 2).Moreover, embodiments discussed herein are directed to an orbital welder configured to weld about a circular workpiece, such as a pipe or tube, generally along a circular path. However, it should be noted that various features discussed herein can be applied in other implementations, such as for a welding system configured to provide a weld generally along a linear path.

[0040] FIG. 2 is a front perspective view of an orbital welder 400 coupled to a workpiece 402 (e.g., a pipe, a tube) having a circular structure. The orbital welder 400 is configured to perform a welding process, such as tungsten inert gas (TIG) wielding, for the workpiece 402. The orbital welder 400 includes a first module 404 (e.g., a first section) and a second module 406 (e.g.. a second section). The first module 404 includes a first module housing 408, and the second module 406 includes a second module housing 410. The first module housing 408 and the second module housing 410 are configured to surround at least a portion of the workpiece 402. For example, the workpiece 402 may extend along a longitudinal axis 412, and each of the first module housing 408 and the second module housing 410 may extend generally parallel to the longitudinal axis 412. The first module housing 408 and the second module housing 410 also cooperatively form a space 414 therebetween in which the workpiece 402 may be positioned for coupling to the first module housing 408 and / or to the second module housing 410. As an example, the module housings 408, 410 may, in some instances, form a V-shaped configuration such that the space 414 is open to facilitate positioning of the workpiece 402 therein. A link or bridge 416 positioned external to the space 414 is coupled to the first module housing 408 and to the second module housing 410 to fix the first module housing 408 and the second module housing 410 to one another (e.g., to maintain a size of the space 414). The link 416 is configured to close the space 414 after the w orkpiece 402 is positioned in the space 414, thereby holding the workpiece 402 within the space 414 to secure the first module housing 408 and / or the second module housing 410 to the workpiece 402.

[0041] In some embodiments, the first module housing 408 and the second module housing 410 are pivotably or rotatably coupled to one another. As an example, the first module housing 408 and the second module housing 410 are coupled to one another via a pivot 418, and the first module housing 408 and the second module housing 410 are configured to rotate relative to one another at the pivot 418 and about a rotational axis 420, which extends substantially parallel to the longitudinal axis 412. Rotation of the first module housing 408 and the second module housing 410 relative to one another adjusts a size of the space 414 and, therefore, adjusts how the orbital welder 400 can accommodate the workpiece 402 in the space 414.

[0042] In particular, relative rotation between the first module housing 408 and the second module housing 410 to increase an angle 422 formed between the first module housing 408 and the second module housing 410 increases a size of the space 414, whereas relative rotation between the first module housing 408 and the second module housing 410 to reduce the angle 422 reduces a size of the space 414. Thus, the first module housing 408 and the second module housing 410 are adjustable to accommodate differently sized workpieces 402. As such, a single embodiment of the orbital welder 400 can couple to each of a plurality of workpieces 402 of different sizes, thereby increasing flexibility of the orbital welder 400 to weld different workpieces 402 (e.g., to avoid having to use multiple embodiments of orbital welders to weld differently sized workpieces 402). Because of the adjustable positioning between the module housings 408, 410, a differently sized link 416 may be utilized to span differently sized distances formed between the module housings 408, 410 for fixing the module housings 408, 410 to one another. Alternatively, an adjustable or extendable link 416 may be utilized to connect module housings 408 and 410.

[0043] In the illustrated embodiment, the orbital welder 400 is in a first configuration 424 (e.g.. a condensed / compact configuration) configured to accommodate a smaller workpiece 402 (e.g., a workpiece 402 having an outer diameter below 2.5 centimeters (cm) or 1 inch). Specifically, in the first configuration 424, the first module housing 408 and the second module housing 410 extend beyond (e.g., radially beyond) the workpiece 402 positioned in the space 414. That is, a portion of the workpiece 402 overlapping with the module housings 408, 410 along the longitudinal axis 412 is contained entirely within the space 414. For this reason, the link 416 extending from the first module housing 408 to the second module housing 410 external to the space 414 is offset from the workpiece 402. For instance, the link 416 extends relatively linearly across the space 414 and remains clear from (e.g.. does not contact) the workpiece 402.

[0044] The orbital welder 400 also includes a weldhead assembly 426 configured to perform the welding process for the workpiece 402. In the illustrated embodiment, the weldhead assembly 426 is coupled to the second module housing 410 via a linkage system 432 (e.g.. a plurality of segments that are able to move, such as rotate, relative to one another). Additionally, the weldhead assembly 426 includes a guide 428 (e.g., a wire feeder) and a torch 430 (e.g., a tungsten electrode). The guide 428 is configured to provide a filler material (e.g., a metal wire) toward the workpiece 402, and the torch 430 is configured to generate an arc between the workpiece 402 and the torch 430 to melt the filler material onto the workpiece 402 and therefore provide a weld on the workpiece 402. However, the term “guide’’ should not beinterpreted to impart any functionality to guide or force the fdler material to move in a specific direction. In some embodiments, the guide 428 may push and / or pull a fill wire towards torch 430, but in other embodiments, the guide 428 may simply guide a fill wire in a certain direction without pushing, pulling, or otherwise imparting a force to the fill wire.

[0045] The orbital welder 400 is configured to move the torch 430 relative to the workpiece 402 during the welding process to provide one or more welds around the workpiece 402. such as about a weld seam 434 (e.g., where two or more components or portions of the workpiece 402 adjoin and are to be welded to one another). To this end, the first module 404 includes a first motor 436 (e.g., a travel motor) configured to drive movement of the first module housing 408 and the second module housing 410, and therefore of the weldhead assembly 426 coupled to the second module housing 410, around the workpiece 402. As such, operation of the first motor 436 enables the weldhead assembly 426 to provide a weld that at least partially surrounds a circumference of the workpiece 402.

[0046] Additionally, the orbital welder 400 includes a second motor 438 (e.g., an automatic voltage control motor) configured to move the weldhead assembly 426 toward and away from the workpiece 402 to accommodate various travel ranges depending on the position of the torch 430 relative to the longitudinal axis 412. For example, as further described herein, the second motor 438 is configured to contact and move the linkage system 432 relative to the second module housing 410, thereby moving the weldhead assembly 426 coupled to the linkage system 432 relative to the second module housing 410. Movement of the weldhead assembly 426 toward and away from the workpiece 402 may adjust the arc generated between the workpiece 402 and the torch 430 by changing the voltage of the arc. In particular, the second motor 438 operates to regulate the voltage of the arc to desirably melt the filler material provided by the guide 428, such as to provide a smooth weld around the workpiece 402. As such, the second motor 438 helps adjust the position of the torch 430 to allow for greater control of a weld.

[0047] The orbital welder 400 further includes a third motor (not shown in FIG. 2) configured to move the weldhead assembly 426 along the longitudinal axis 412 relative to the second module housing 410. For instance, the third motor may move the linkage system 432 along the longitudinal axis 412 to drive movement of the weldhead assembly 426 coupled to the linkage system 432 along the longitudinal axis 412. Such movement of the weldhead assembly 426 causes the weld provided by the weldhead assembly 426 to extend across the weld seam 434, thereby increasing a surface area covered by the weld at the weld seam 434 to produce a more secure weld. Thus, operation of the third motor during the welding process improves the welding process provided to the work piece 402.

[0048] In the depicted embodiment, the first motor 436 is disposed in the first module housing 408, and the second motor 438 and the third motor are disposed in the second module housing 410. Such arrangement of the motors 436, 438 limits a footprint occupied by the orbital welder 400 to enable greater flexibility7in placement of the orbital welder 400. That is, the first module housing 408 and the second module housing 410, which are used to secure the orbital welder 400 to the workpiece 402, and the motors 436. 438, which operate to move the weldhead assembly 426 relative to the workpiece 402. share at least a common volume. Thus, the overall volume occupied by the orbital welder 400 is reduced relative to that of an arrangement in which the motors 436, 438 are disposed external to the module housings 408, 410 (i.e., and therefore do not share a common volume). For example, such compact arrangement of the orbital welder 400 enables placement in small spaces, such as spaces within a low radial clearance of 3.8 cm or 1.5 inches from the workpiece 402.

[0049] The orbital welder 400 additionally includes one or more sensors 440 configured to monitor a welding process executed by the orbital welder 400. For instance, the sensor(s) 440 may include an optical sensor (e.g., a camera or other imaging device) configured to capture image data of the weld provided via operation of the weldhead assembly 426. To this end. the sensor(s) 440 are mounted adjacent to the torch 430 as part of the weldhead assembly 426 and are oriented toward the torch 430. In certain embodiments, the motors 436, 438 are configured to operate automatically based on data received from the sensor(s) 440. For example, the orbital welder 400 may include or be communicatively coupled to a control system 442 (e.g., a programmable controller, an electronic controller, an automation controller, a computer device, control circuitry), which may be disposed in any location of the welding system 2 (as mentioned above)

[0050] The control system 442 is communicatively coupled to the sensor(s) 440 and is configured to receive data (e.g., image data) from the sensor(s) 440. The control system 442 is configured to use the received data to adjust operation of the motors 436, 438. As an example, in response to determining the filler material is being insufficiently melted by the torch 430, the control system 442 may instruct the second motor 438 to move the torch 430 relative to (e.g., toward) the workpiece 402 to adjust the arc being generated to melt the filler material more desirably. Additionally or alternatively, the control system 442 is configured to provide an output based on the data received from the sensor(s) 440. For instance, the control system 442 may be configured to display the image data captured by the sensor(s) 440 to a user (e.g., an operator, a technician). As a result, the user is able to observe the operation of the weldhead assembly 426 and may adjust (e.g., manually adjust) operation based on the imagedata (e.g., to adjust a position or movement of the weldhead assembly 426 to improve the weld being provided). Indeed, because of the potential arrangement of the orbital welder 400 with respect to the workpiece 402, access and exposure of the weld seam 434 between the torch 430 and the workpiece 402 may be limited. Therefore, image data captured by the sensor(s) 440 may provide visibility of the operation of the weldhead assembly 426 that otherwise may not be readily available. In any case, cooperative operation between the control system 442 and the sensor(s) 440 may improve the welding process provided by the orbital welder 400.

[0051] FIG. 3 is a rear perspective view of the orbital welder 400. The first module 404 includes a first cooling plate 500 coupled to the first module housing 408 and configured to provide cooling to components (e.g., the first motor 436) disposed in the first module housing 408. For instance, the first cooling plate 500 may be configured to receive a cooling fluid (e.g., cooled water) and direct the cooling fluid to absorb heat from the components to reduce a temperature of or limit an increase in temperature of the components disposed in the first module housing 408. To this end, the first cooling plate 500 includes first ports 502 (e.g., a first inlet port, a first outlet port). One of the first ports 502 is configured to receive the cooling fluid (e.g., from a cooling fluid source configured to store cooled flows of the cooling fluid) for cooling the components, and another of the first ports 502 is configured to discharge cooling fluid (e.g., to the cooling fluid source) that has absorbed heat from the components. Thus, the first ports 502 circulate cooling fluid to provide cooling for the first module 404.

[0052] Similarly, the second module 406 includes a second cooling plate 504 coupled to the second module housing 410 and configured to provide cooling to the components (e g., the second motor 438, the third motor) disposed in the second module housing 410. As such, the second cooling plate 504 includes second ports 506 (e.g., a second inlet port, a second outlet port) configured to circulate cooling fluid (e.g., the same or different cooling fluid as that circulated via the first ports 502) to provide cooling for the second module 406. Further still, the weldhead assembly 426 includes third ports 508 (e.g., a third inlet port, a third outlet port) configured to circulate cooling fluid (e.g., the same or different cooling fluid as that circulated via the first ports 502 and / or the second ports 506) through the weldhead assembly 426 to provide cooling for the weldhead assembly 426 (e.g., the torch 430). The cooling provided to various components of the orbital welder 400 may facilitate operation of the orbital welder 400 and / or prolong a useful lifespan of the orbital welder 400.

[0053] Although the present disclosure primarily discusses circulating a cooling fluid to provide cooling (e.g., via conduction), in additional or alternative embodiments, cooling may be provided in a different manner for the orbital welder 400. By way of example, a fan maydirect an airflow across components of the orbital welder 400 to remove heat via convection. In any case, cooling may be provided to the orbital welder 400 concurrently during operation of the orbital welder 400 to perform the welding process.

[0054] FIG. 4 is an exploded view of the orbital welder 400 illustrating assembly of the orbital welder 400 to couple to the workpiece 402. In the illustrated embodiment, the workpiece 402 is positioned external to the space 414, and the link 416 is decoupled from the module housings 408, 410 to open the space 414. As such, a guide assembly 550 (e.g., a guide ring assembly) coupled to the workpiece 402 is visible. The guide assembly 550 facilitates coupling of the orbital welder 400 to the workpiece 402. For example, the guide assembly 550 may include a clamp 552 configured to secure to the workpiece 402, as well as a track 554 attached to the clamp 552. During operation of the orbital welder 400, the guide assembly 550 remains fixed to the workpiece 402 (e.g., the clamp 552 and the track 554 do not rotate around the workpiece 402).

[0055] Additionally, the orbital welder 400 includes a wheel 556 (e.g., a geared shaft) configured to rotate along track 554 via the first motor 436. More specifically, in the depicted embodiment, the wheel 556 is exposed to the space 414 and includes teeth that are configured to engage with corresponding teeth of the track 554 in an assembled configuration of the orbital welder 400. Engagement between the wheel 556 and the track 554 couples the modules 404, 406 to the guide assembly 550 and to the workpiece 402 via the guide assembly 550. Additionally, operation of the first motor 436 to rotate the wheel 556 relative to the module housings 408, 410 causes the teeth of the wheel 556 to interact with teeth of the track 554, which rolls and moves the wheel 556 around the track 554, thereby driving movement of the module housings 408, 410 around the track 554 and the workpiece 402 (e.g.. about the longitudinal axis 412). As such, the wheel 556 can cause the weldhead assembly 426 to rotate around the workpiece 402 to create a weld extending about a circumference of the workpiece 402. Although the wheel 556 is rotatably coupled to the second module housing 410 in the illustrated embodiment, in additional or alternative embodiments, the wheel 556 or another wheel is coupled to the first module housing 408. For example, the wheel 556 may be coupled to the first motor 436 disposed in the first module housing 408, and the first motor 436 may be configured to drive rotation of the wheel 556 (e.g., via connection with a series of gears) to cause the module housings 408, 410 to rotate around the workpiece 402.

[0056] Still referring to FIG. 4, the link 416 includes openings 558 to facilitate coupling the link 416 to the module housings 408, 410. By way of example, each module housing 408, 410 may include a pair of mounts 560 extending external of the space 414. Each end of thelink 416 is configured to be positioned between a corresponding pair of the mounts 560 to align each opening 558 of the link 416 with respective holes 562 formed through the mounts 560. A respective fastener 564 (e.g., pin) is configured to be inserted through the aligned openings 558 and holes 562 to secure ends of the link 416 to the mounts 560. However, in other embodiments, the link 416 may be secured to module housings 408, 410 in any manner now known or developed hereafter and may, for example, be fixedly coupled to one of module housings 408 and 410 (e.g., at a pivot) and removably coupled to another of the module housings 408, 410 (e.g., via a latch). Securing the link 416 to the mounts 560 restricts movement of the module housings 408, 410 relative to one another. Consequently, engagement between the wheel 556 and the track 554 may be maintained.

[0057] In certain embodiments, the link 416 may be adjustable. As an example, the link 416 may include a biasing member 566 or other adjustable mechanism spanning from or at least partially between one opening 558 and the other opening 558 at the ends of the link 416. The biasing member 566 imparts a force at the ends of the link 416 (e.g., within the openings 558) such that extending the fasteners 564 through the mounts 560 and the openings 558 causes the biasing member 566 to impart a force (e.g.. tension) onto the fasteners 564 at the ends of the link 416. The biasing member 566 may be tightened to increase the force imparted onto the fasteners 564, thereby restricting movement of the fasteners 564 relative to the mounts 560 and increasing securement of the link 416 to the module housings 408, 410. Additionally, the biasing member 566 may be loosened to reduce the force imparted onto the fasteners 564. such as to facilitate decoupling of the fasteners 564 from the module housings 408, 410. In certain embodiments, the link 416 includes an aperture 568 configured to enable interfacing with the biasing member 566. As an example, the aperture 568 may include a screw or fastener that can be rotated to adjust the stiffness of the biasing member 566 to adjust the force imparted onto the fasteners 564.

[0058] FIG. 5 is a side perspective view of the orbital welder 400 in which certain parts of the first module housing 408 are not shown to increase visibility of some components disposed in the first module housing 408. As shown, the first motor 436 disposed in the first module housing 408 can be seen generally extending parallel to the longitudinal axis 412. The first motor 436 may therefore be arranged within the first module housing 408 to couple to and drive rotation of the wheel 556 to move the orbital welder 400 around the workpiece 402.

[0059] Moreover, a first adjustment element 600 (e.g., a set screw) is configured to adjust the position of the wheel 556 relative to the first module housing 408. In particular, the first adjustment element 600 is configured to move the wheel 556 toward and away from the space414. Such movement of the wheel 556 adjusts a position of the first module housing 408 relative to the track 554 (not shown in FIG. 5) and the workpiece 402 to which the track 554 is secured. By way of example, the first module housing 408 and the second module housing 410 may initially be positioned relative to one another to surround the workpiece 402, and the first adjustment element 600 may then be used enable the wheel 556 to engage with the track 554.

[0060] More specifically, the first adjustment element 600 may be used to adjust the position of the wheel 556 to enable the orbital welder 400 to secure to the track 554 and therefore to the workpiece 402 without having to adjust (e g., rotate) the positioning of the module housings 408, 410, such as to change a size of the space 414. As such, the position of the module housings 408, 410 relative to one another may be maintained while the position of the wheel 556 is adjusted to accommodate a particularly sized workpiece 402 (e.g., to enable the orbital welder 400 to secure to differently sized workpieces 402 without having to move the module housings 408, 410 relative to one another). This may make the orbital w elder 400 easy to install onto w orkpieces 402 of varied sizes disposed within the space 414. In certain implementations, the first adjustment element 600 is used to adjust the wheel 556 and move the first module housing 408 relative to the workpiece 402 to adjust a clearance between the first module housing 408 and the workpiece, such as to provide sufficient clearance that avoids contact betw een the first module housing 408 w ith the workpiece 402 during operation of the orbital welder 400, while limiting the overall physical footprint occupied by the orbital welder 400 (e.g., the orbital welder 400 extends radially from the workpiece 402 to a distance that is less than 3.8 cm or 1.5 inches). In some embodiments, the first module housing 408 includes a first aperture 602 that exposes the first adjustment element 600, thereby providing access to the first adjustment element 600 for adjusting the position of the wheel 556 relative to the space 414.

[0061] Further still, a second adjustment element 604 (e.g., a screw) may securely position the weldhead assembly 426 with respect to the workpiece 402. Specifically, the second adjustment element 604 is configured to enable or block functionality of the first adjustment element 600. For example, loosening the second adjustment element 604 (e.g.. by moving the second adjustment element 604 away from the first adjustment element 600) may enable the first adjustment element 600 to adjust the positioning of the w heel 556, w hereas tightening the second adjustment element 604 (e.g., by moving the second adjustment element 604 toward the first adjustment element 600) may block the first adjustment element 600 from adjusting the position of the wheel 556.

[0062] In the illustrated embodiment, a sensor 608 (e.g., an encoder, a tachometer, such as installed as a part of the first motor 436) is disposed in the first module housing 408. The sensor 608 is configured to monitor a parameter indicative of movement of the torch 430 around the workpiece 402. In an example, the parameter includes or is motion or a position, but the parameter can include any other suitable parameter (e.g., electrical properties) in additional or alternative embodiments. The parameter may be used (e.g., by the control system 442) to operate any of the motors 436, 438 to adjust the position of the weldhead assembly 426. such as to change the distance between the torch 430 and the workpiece 402 at a certain rotational position. In addition, an electrical filter 610 (e.g., a choke, an inductor) is disposed in the first module housing 408 and is configured to filter signals, such as arc voltage feedback used by the control system 442, for usage by the orbital welder 400. For example, the electrical filter 610 may block high frequency signals and / or low frequency signals from passing to remove noise and facilitate communication between components of the orbital welder 400, thereby enabling desirable operation of the orbital w elder 400.

[0063] FIG. 6 is a side perspective view of the orbital welder 400 in which certain parts of the second module housing 410 are not shown to increase visibility of some components disposed in the second module housing 410. At least a portion of the linkage system 432 coupled to the weldhead assembly 426 extends into the second module housing 410 to contact the second motor 438 disposed in the second module housing 410. For example, the second motor 438 may include a cam 650 (e.g., positioned eccentrically about an axis of rotation of the second motor 438) configured to abut the linkage system 432 (e.g., a movable bracket 651 of the linkage system 432). That is, the cam 650 may rest in an elongated slot 653 of the bracket 651 such that the linkage system 432 converts rotational movement of the cam 650 into motion (e.g., rotational motion) of the movable bracket 651 to drive movement of the weldhead assembly 426. Thus, operation of the second motor 438 moves the cam 650, which correspondingly drives movement of the movable bracket 651 of the linkage system 432 and of the weldhead assembly 426 coupled to the linkage system 432. For instance, the cam 650 may move the movable bracket 651 to cause the linkage system 432 to rotate about a rotational axis 652. and the linkage system 432 may convert this rotation to move (e.g., rotate) the torch 430 toward and away from the workpiece 402. In some embodiments, a bushing is placed on the cam 650 to facilitate driving of the linkage system 432. The engagement between the cam 650 and the linkage system 432 to drive movement of the weldhead assembly 426 may prolong a useful lifespan of the linkage system 432 and of the second motor 438, such as in comparisonto an arrangement in which gears are in constant engagement and interaction with one another to couple the linkage system 432 and the second motor 438 to one another.

[0064] The third motor 654 (e.g., an oscillation motor) is disposed in the second module housing 410 and is also coupled to a portion of the linkage system 432, but in a manner that causes the linkage system 432 and the weldhead assembly 426 to move along the longitudinal axis 412. By way of example, a bracket 656 of the third motor 654 is configured to engage with the linkage system 432 and slide along the longitudinal axis 412 (e.g.. via rotation of a threaded screw and nut engagement) to move the linkage system 432 and the weldhead assembly 426 along the longitudinal axis 412, and therefore along the rotational axis 420 parallel to the longitudinal axis 412, relative to the second module housing 410 and the workpiece 402. In certain embodiments, the third motor 654 is configured to move (e.g., oscillate) the weldhead assembly 426 - and therefore the torch 430 - back and forth along approximately 2.5 cm or 1 inch (e.g., 1.9 cm or 0.75 inches) of travel. Another sensor 658 (e.g., a potentiometer) is configured to monitor the position of the torch 430 along the longitudinal axis 412, and data from the sensor 658 may be used to operate any of the motors 436, 438. 654 to move the torch 430 relative to the workpiece 402.

[0065] In embodiments in which there is a wheel 556 coupled to the second module housing 410, a third adjustment element 660 (e.g., a set screw) is configured to adjust the position of the wheel 556 relative to the second module housing 410, such as toward and away from the space 414 (e.g., after the first module housing 408 and the second module housing 410 have initially been positioned relative to one another to surround the workpiece 402). Thus, the third adjustment element 660 may provide sufficient clearance between the second module housing 410 and the w orkpiece 402 to avoid contact of the second module housing 410 with the workpiece 402 during operation of the orbital welder 400. In such embodiments, the second module housing 410 includes an aperture 662 that exposes the third adjustment element 660 to facilitate access to the third adjustment element 660.

[0066] Although the motors 436, 438, 654 are positioned within the respective module housings 408, 410. the extension of the module housings 408, 410 along the longitudinal axis 412 may be limited. Indeed, a dimension 664 (e.g.. a length) of the module housings 408, 410 may be sized (e g., between 9 cm or 3.5 inches to 14 cm or 5.5 inches) to accommodate positioning of the motors 436, 438, 654 therein but is limited to reduce an overall physical footprint occupied by the orbital w elder 400. Therefore, the size of the module housings 408, 410 may further help enable flexible positioning of the orbital welder 400. The limited size ofthe module housings 408, 410 may also reduce an amount of material used to manufacture the orbital welder 400 and reduce a weight of the orbital welder 400.

[0067] FIG. 7 is a perspective view of the weldhead assembly 426. The weldhead assembly 426 includes a base 700 configured to couple to the linkage system 432, the guide 428 coupled to the base 700, a gas cup 702 coupled to the base 700, and the torch 430 coupled to the gas cup 702. The sensors 440 are also coupled to the base 700 and are positioned on opposite sides of the gas cup 702 and therefore of the torch 430. The gas cup 702 is configured to direct gas (e.g., shield gas) around the torch 430 to facilitate generating and maintaining the arc used for melting filler material. The guide 428 extends from the base 700 in an arcuate manner to extend around the gas cup 702 for directing filler material toward the torch 430. However, other embodiments might include different arrangements of the foregoing components and / or might include additional or different components.

[0068] The weldhead assembly 426 includes various adjustment elements that can be used to adjust (e.g., manually adjust) the torch 430 and / or the guide 428. For example, a first adjustment element 704 (e.g., a first screw) may be used to adjust a position of the torch 430 (e.g.. an amount of extension of the torch 430 from the gas cup 702), a second adjustment element 706 (e g., a second screw) may be used to adjust a position of the guide 428 alongside the torch 430, a third adjustment element 708 (e.g., a third screw) may be used to translate the guide 428 toward and away from the gas cup 702 (e.g., to slide the guide 428 up and down relative to the torch 430 and a workpiece), a fourth adjustment element 710 (e.g.. a fourth screw) may be used to rotate the guide 428 (e.g., about an axis of extension of the torch 430), and a fifth adjustment element 712 (e.g., a fifth screw) may be used to adjust an orientation, such as a tilt angle, of the guide 428 relative to the torch 430. The adjustment elements 704, 706, 708. 710, 712 may be used to direct filler material in a desirable direction for melting by the torch 430 (e.g., via the arc generated by the torch 430).

[0069] FIG. 8 is a bottom view of the weldhead assembly 426. A gas conduit 748 (e.g., a gas inlet) is coupled to the base 700 to enable gas flow, such as to the gas cup 702, for generating and / or shielding the arc. Furthermore, as discussed, the sensors 440 are oriented toward the torch 430 to capture image data of the operation of the torch 430. For this reason, the gas cup 702 forms grooves 750 to avoid obstructing the view of the sensors 440. In other words, the sensors 440 are oriented to face the torch 430 through the grooves 750. Respective light emitters 752 (e.g.. light emiting diodes) are coupled to the sensors 440 and are configured to emit a light toward the torch 430 to illuminate the area surrounding the torch 430 and further facilitate operation of the sensors 440 to capture image data of the operation of the torch 430.

[0070] In the illustrated embodiment, each of the sensors 440 is coupled to a block 754. The block 754 may be composed of a conductive material, such as aluminum, for increased heat transfer and dissipation away from the sensors 440. The block 754 is coupled to the base 700, such as via a bracket 756. Additionally, the block 754 may be cooled by cooling fluid circulated through the weldhead assembly 426 via the third ports 508, further limiting a temperature increase of the sensors 440. In some embodiments, an insulator (e.g., an insulator with high thermal conductivity) is applied between the block 754 and the third ports 508 to electrically insulate the sensor(s) 440 while enabling sufficient heat dissipation through the block 754.

[0071] FIG. 9A is a perspective bottom view of another embodiment of the weldhead assembly 426. The illustrated weldhead assembly 426 has a housing 760 that contains one or more sensors 762, such as optical sensors, configured to capture image data of the operation of the torch 430. The housing 760 is coupled to the base 700, and segments 764 are coupled to the housing 760, such as via a fastener (e.g., a set screw). The housing 760 and the segments 764 cooperatively enclose a substantial portion of each sensor 762. thereby helping shield the sensor(s) 762, such as from slag or other debns, to maintain desirable operation of the sensor(s) 762. Grooves 766 are formed into the gas cup 702 to avoid obstructing the view of the sensor(s) 762 to the torch 430. A light emitter (e.g., light emitting diodes) can also be positioned in the housing 760 (e.g., coupled to the sensor(s) 762) to illuminate the area surrounding the torch 430 to facilitate operation of the sensor(s) 762.

[0072] FIG. 9B is a perspective bottom view of yet another embodiment of the weldhead assembly 426, which is similar to the weldhead assembly 426 of FIG. 9A and includes the housing 760 coupled to (e.g., positioned flush against) the base 700. However, the illustrated weldhead assembly 426 does not include segments or other shielding components shielding the sensor(s) 762. Additionally, the sensor(s) 762 are clamped to the housing 760, such as via a fastener 768.

[0073] FIG. 10 is a front view of the orbital welder 400 coupled to the workpiece 402. In particular, FIG. 10 illustrates the compact arrangement of the orbital welder 400 around the workpiece 402. The illustrated orbital welder 400, including its various cable connection 770 that communicatively couple different components to one another, generally surrounds the workpiece 402 within a circular boundary 772 having a limited diameter 774. In one example, the circular boundary' 772 may have a diameter of less than 10 cm or 3.9 inches. Such a size of the circular boundary 772 provides a clearance 776 of around 3.8 cm or 1.5 inches for a workpiece 402 having a diameter 778 of around 2. 1 cm or 0.84 inches. Thus, the orbital welder400 occupies a limited physical footprint outside of that occupied by the workpiece 402. For this reason, the orbital welder 400 can be positioned within confined spaces to increase the flexibility of implementation of the orbital welder 400.

[0074] FIG. 11 is a perspective view of the orbital welder 400 in a second configuration 800 (e.g., an expanded configuration) to accommodate and perform a welding process for a relatively larger workpiece 802 (e.g., a workpiece 802 having an outer diameter above 5 cm or 2 inches). In the second configuration 800. the first module housing 408 and the second module housing 410 do not extend beyond (e g., radially beyond) the workpiece 802 positioned in the space 414. In other words, a portion of the workpiece 802 overlapping with the module housings 408, 410 along a longitudinal axis 804 extends at least partially out of the space 414. The module housings 408, 410 are rotated relative to one another to increase the angle 422 formed between the module housings 408, 410 and enable the module housings 408, 410 to capture a portion of the circumference of the workpiece 802 having the increased diameter.

[0075] Moreover, a link 806 extends from the first module housing 408 to the second module housing 410 external to the space 414 to fix the first module housing 408 and the second module housing 410 to one another and to the workpiece 802 having the increased diameter. The link 806 has a circular profile to accommodate a shape (e.g., the circumference) of the workpiece 802. In other w ords, the link 806 extends relatively circularly around the workpiece 802 from the first module housing 408 to the second module housing 410. For example, the link 806 may engage with and capture the workpiece 802. An intermediate coupler 807 (e.g., a wedge) is positioned betw een and coupled to exterior parts of the module housings 408, 410 to further secure the module housings 408, 410 to one another for securement to the workpiece 802.

[0076] Despite these differences in components used to couple the orbital welder 400 to the differently sized workpieces 402, 802, the orbital welder 400 is installed onto and operates on the w-orkpiece 802 in a similar manner to how it is installed onto and operates on the workpiece 402. For instance, a guide assembly 808 may be secured around the workpiece 802, and the wheel 556 (not shown in FIG. 11) of the orbital welder 400 may engage with the guide assembly 808 and rotate via operation of the first motor 436 (not shown in FIG. 11) to drive movement of the modules 404, 406 and the weldhead assembly 426 around the workpiece 802. Additionally, the second motor 438 (not shown in FIG. 11) operates to move the weldhead assembly 426 toward and away from the workpiece 802 to adjust an arc used to weld the workpiece 802, and the third motor 654 (not shown in FIG. 11) operates to oscillate theweldhead assembly 426 along the longitudinal axis 804 to move the weld along the longitudinal axis 804.

[0077] FIG. 12 is a front view of the orbital welder 400 coupled to the workpiece 802 via the link 806. As can be seen, the link 806 includes arms 850 that extend from the respective module housings 408, 410, and opposite ends of the arms 850 extend to a connector 852. The link 806 also includes wheels 854 coupled to the arms 850. The wheels 854 are configured to surround the workpiece 802. An adjustment mechanism 856 (e.g.. a latch) coupled to the connector 852 is configured to adjust a force (e g., tension) imparted by the connector 852 onto the arms 850 and correspondingly onto the module housings 408, 410 at the respective ends of the link 806 to adjust securement of the link 806 onto the workpiece 802. For instance, the adjustment mechanism 856 may initially be positioned to reduce the force imparted by the connector 852 onto the arms 850 and onto the module housings 408, 410, which positions (e.g., opens) the arms 850 to provide clearance between the wheels 854 and the workpiece 802, thereby allowing the link 806 to be moved relative to the workpiece 802 along the longitudinal axis 804. Additionally, the adjustment mechanism 856 may be moved to increase the force imparted by the connector 852 onto the arms 850 and onto the module housings 408. 410. which moves (e.g., closes) the arms 850 to engage the wheels 854 with the workpiece 802, thereby causing the wheels 854 to cooperatively capture the workpiece 802. Consequently, movement of the link 806 relative to the workpiece 802 along the longitudinal axis 804 may be restricted. However, the wheels 854 are configured to rotate and therefore enable the link 806 to rotate around the workpiece 802, such as about the longitudinal axis 804. As such, while the link 806 is secured to the workpiece 802, the wheels 854 help the orbital welder 400 coupled to the link 806 travel around the workpiece 802 to provide a weld extending along at least a portion of the circumference of the workpiece 802.

[0078] A differently sized link 806 may be used to secure the orbital welder 400 to a differently sized workpiece 802. As an example, links 806 may have differently sized diameters to accommodate workpieces 802 of different sizes. However, each link 806 may include similar features, such as arms 850, a connector 852. wheels 854, and an adjustment mechanism 856 to enable securement of the link 806 to a corresponding workpiece 802, while enabling rotation of the link 806 about the workpiece 802. Alternatively, different links may include different features.

[0079] The orbital welder 400 is described as being positioned external to the workpieces 402, 802 (e.g., beyond an outer diameter of the workpieces 402, 802) to provide a weld along an outer surface of the workpieces 402, 802. However, the orbital welder 400 may additionallyor alternatively be positioned within a workpiece to provide a weld along an inner surface 901 of the workpiece. FIG. 13 is a front view of the orbital welder 400 (e.g.. in the second configuration 800) positioned within a workpiece 900 to perform a welding process along an inner surface 901 of the workpiece 900. In such instances, a guide tube / pipe 903 of another guide assembly is smaller than the workpiece 900 and is secured to a position within the workpiece 900 to extend through (e.g., concentrically through) the workpiece 900.

[0080] The orbital welder 400 is secured around the guide tube 903 and arranged such that the torch 430 faces the inner surface 901. In the depicted embodiment, a link 902 couples the first module housing 408 and the second module housing 410 to one another and secures the orbital welder 400 to the guide tube 903. However, it is also possible for the orbital welder 400 to be secured to the inner surface of a workpiece without a guide tube 903, e.g., by way of the link 902 arranged to engage the inner surface 901 of the workpiece 900.

[0081] The link 902 includes arms 904 extending from the respective module housings 408, 410 to a connector 906. Wheels 908 are coupled to the arms 904, and an adjustment mechanism 910 (e.g., a latch) is configured to adjust a force imparted by the connector 906 onto the arms 904 to engage the wheels 908 with the guide tube 903. In some instances, the wheels 908 may also engage the inner surface 901 of the w orkpiece 900. Either way, during engagement with the guide tube 903, the wheels 908 are configured to rotate to enable the orbital welder 400 to move around he guide tube 903 and correspondingly along the inner surface 901 around a longitudinal axis 912 along which the workpiece 900 extends. Accordingly, the orbital welder 400 is able to perform a welding process on an outer surface or an inner surface of a w orkpiece, further increasing fl exi bi 1 i ty of operation of the orbital welder 400 to perform welding processes.

[0082] Each of FIGs. 14 and 15 illustrates a method related to an orbital welder (e.g., the orbital welder 400). It should be noted that the operations of each method may be performed differently than depicted. For example, an additional operation may be performed for one of the methods, an operation of one of the methods may be performed differently, operations of one of the methods may be performed in a different order, and / or an operation of one of the methods may not be performed.

[0083] FIG. 14 is a flowchart of a method 950 for coupling an orbital welder to a workpiece with a surface (e.g., an outer surface, an inner surface) to be wielded. At block 952, a guide assembly is disposed at the workpiece. In some embodiments, the guide assembly surrounds and secures to an exterior of the workpiece (e.g., via a clamp). In additional or alternativeembodiments, the guide assembly is disposed within and extended through the workpiece. The guide assembly includes a gear with teeth.

[0084] At block 954, a first module and a second module of the orbital welder are rotated to extend along the surface of the workpiece. The positioning of the first module and the second module forms a space between a first module housing of the first module and a second module housing of the second module for receiving the workpiece. The space is open to enable the orbital welder to be positioned in the space such that a wheel coupled to the first module housing or to the second module housing is engaged with the gear of the guide assembly.

[0085] At block 956, an adjustment element (e.g., a screw) is used to move the wheel relative to the first module housing and relative to the second module housing. In particular, the adjustment element moves the wheel toward and away from the space between the first module housing and the second module housing to engage the wheel with the gear and provide sufficient clearance between the module housings and the surface of the workpiece. Such clearance enables the orbital welder to move along the surface and avoid contact between the module housings and the workpiece. In some embodiments, an additional adjustment element (e.g.. an additional screw) is used to secure the first module with respect to the workpiece, such as by blocking movement of the wheel toward or away from the space. Consequently, the additional adjustment element increases rigidity of the orbital welder to increase positional control. Moreover, in certain implementations, another adjustment element may be used to align a weldhead of the orbital welder with a weld seam of the surface to be welded, such as by moving the module housings, and therefore the weldhead coupled to one of the module housings, relative to the wheel along a longitudinal axis of the workpiece to align a torch of the weldhead with the weld seam along the longitudinal axis.

[0086] At block 958, a link is coupled to the first module (e.g., the first module housing) and the second module (e.g., the second module housing) to secure the first module and the second module to one another and to the workpiece. For instance, ends of the link are positioned between mounts of the modules to align openings of the link with holes of the mount, and fasteners are inserted through the aligned openings and holes to couple the link to each module. The link fixes the first module and the second module to one another and also closes the space between the first module housing and the second module housing, thereby maintaining engagement of the wheel to the gear of the guide assembly.

[0087] In some embodiments, the workpiece does not extend radially beyond the module housings of the orbital welder. That is, a portion of the workpiece is contained entirely within the space between the module housings. In such embodiments, the link extends (e.g., relativelylinearly) over the workpiece positioned within the space formed between the module housings. The clearance between the link and the workpiece facilitates rotation of the module housings about the housings by avoiding contact between the link and the workpiece. Alternatively, the workpiece extends radially beyond the module housings (i.e., the workpiece extends out of the space), and the link extends (e.g., relatively circularly) about the surface of the workpiece. In such embodiments, the link includes wheels configured to engage the surface of the workpiece. The wheels are configured to rotate to facilitate movement of the module housings along the surface. In either case, the link imparts a force at respective ends of the link coupled to the module housings to block relative movement between the module housings, thereby fixing the module housings to one another. In some embodiments, the link is adjustable to change the force being imparted at the respective ends, which may help position the orbital welder desirably before securement to the workpiece.

[0088] Operations similar to those discussed with respect to FIG. 14 may be performed to decouple an orbital welder from a workpiece, such as after a weld has been formed on the workpiece. For instance, the link may be decoupled from the first module and from the second module, the adjustment element may be adjusted to disengage the wheel from the gear of the guide assembly (e.g., after the additional adjustment element is adjusted to enable movement of the wheel away from the space betw een the module housings), and the modules may be rotated (e.g., to increase a size of the space between the module housings) to enable the workpiece to be removed from the space. The guide assembly may also be decoupled from the workpiece to allow the workpiece to be used without the guide assembly attached thereto.

[0089] FIG. 15 is a flowchart of a method 1000 for operating an orbital welder. For example, the method 1000 may be performed after performance of the method 950 such that the orbital welder is coupled to a workpiece. At block 1002, a first motor of the orbital welder is operated to move a weldhead assembly of the orbital welder around the workpiece. By way of example, the orbital welder may include a wheel configured to engage with a gear secured around the workpiece, and the first motor may rotate the wheel to interact with the gear and drive movement of the weldhead assembly around the workpiece.

[0090] At block 1004, a second motor is operated to move the weldhead assembly toward and aw ay from the w orkpiece. Such movement of the weldhead assembly changes a property (e.g., a voltage) of an arc generated by the w eldhead assembly, thereby changing melting of a filler material to provide a weld onto the workpiece. In some embodiments, the weldhead assembly is coupled to a module housing of the orbital welder via a linkage, and the secondmotor is configured to move (e.g., rotate) the linkage to move the weldhead assembly toward and away from the workpiece.

[0091] At block 1006, athird motor is operated to move the weldhead assembly along (e.g., linearly along) an axis of extension of the workpiece. Such movement of the weldhead assembly helps increase an area covered by the weld provided onto a weld seam of the workpiece to be welded, thereby increasing strength of the weld. The third motor is configured to oscillate the linkage back and forth along the axis to drive movement of the weldhead assembly along the axis.

[0092] Therefore, separate motors of the orbital welder are configured to drive different ty pes of movement of the orbital welder relative to the workpiece. Consequently, movement of the orbital welder may be more acutely controlled. However, in some embodiments, a single motor may be configured to drive different types of movement of the orbital welder. By way of example, a motor may be configured to move the weldhead assembly toward and away from the workpiece and also along the axis of extension of the workpiece. In any case, the motors may be disposed within the module housings that are used to secure the orbital welder to the workpiece. Thus, the module housings and the motors occupy at least some common amount of volume to limit an overall physical footprint occupied by the orbital welder (e g., in comparison to an orbital welder with motors that are separate from module housings).

[0093] Moreover, in certain embodiments, the motors are configured to move the weldhead assembly based on sensor feedback. For example, such feedback may include image data of the operation of the weldhead assembly (e g., a quality or property of the weld provided by the weldhead assembly), a voltage of the arc generated by the weldhead assembly, a position of the weldhead assembly relative to the workpiece (e.g., along the axis of extension), and / or any other suitable feedback. Consequently, the motors may operate automatically based on the feedback to perform a welding process more desirably.

[0094] FIG. 16 illustrates a hardware block diagram of a computing device 1300 that may execute the techniques presented herein. This computing device 1300 may be included in or formed from portions of any combination of parts included in the control system 442, such as a real time control section, of the orbital welder 400. Thus, the control system 442 may execute the techniques presented herein (e.g., the operations of the method 1000), alone or in combination with one or more other systems / components.

[0095] As depicted, the computing device 1300 includes a bus 1308, which provides communications between processor(s) 1302, one or more memory elements 1304, persistent storage or memory 1306, one or more network processor units 1310 (i.e., a communicationsunit), and input / output (I / O) interface(s) 1314. The bus 1308 can be implemented with any architecture designed for passing data and / or control information between processors (such as microprocessors, communications and network processors, control boards, etc.), system memory, peripheral devices, and any other hardware components within a system. For example, the bus 1308 can be implemented with one or more buses.

[0096] The memory 1306 and / or memory element 1304 may include random access memory (RAM) or other dynamic storage devices (i.e.. dynamic RAM (DRAM), static RAM (SRAM), and synchronous DRAM (SD RAM)), for storing information and instructions to be executed by the processor 1302. The memory 1306 and / or memory7element 1304 may also include a read only memory (ROM) or other static storage device (i.e., programmable ROM (PROM), erasable PROM (EPROM), and electrically erasable PROM (EEPROM)) for storing static information and instructions for the processor 1302. Additionally, although “control logic” 1320 is illustrated separately from the memory71306 and / or memory element 1304, the control logic 1320 may be stored as non-transitory computer-readable instructions in the memory 1306 and / or memory element 1304, for execution by the processor 1302 so that the processor 1302 can execute the techniques presented herein.

[0097] Although FIG. 16 shows the processor 1302 as a single box, it should be understood that the processor 1302 may represent a plurality7of processing cores, each of which can perform separate processing. The processor 1302 may also include special purpose logic devices (i.e.. application specific integrated circuits (ASICs)) or configurable logic devices (i.e., simple programmable logic devices (SPLDs), complex programmable logic devices (CPLDs), and field programmable gate arrays (FPGAs)), that, in addition to microprocessors and digital signal processors may individually, or collectively, are types of processing circuitry7.

[0098] The processor 1302 performs a portion or all of the processing steps required to execute the techniques presented herein, e.g., in response to instructions received at the network processor unit(s) 1310 and / or instructions contained in the memory7element 1304 and / or memory71306. Such instructions may be read into the memory element 1304 and / or memory 1306 from another computer-readable medium. One or more processors in a multi-processing arrangement may also be employed to execute the sequences of instructions contained in the memory element 1304 and / or memory 1306. In alternative embodiments, hard-wired circuitry may be used in place of or in combination with software instructions. Thus, embodiments are not limited to any specific combination of hardware circuitry and software. Put another way, the computing device 1300 includes at least one computer-readable medium or memory for holding instructions programmed according to the embodiments presented, for containing datastructures, tables, records, or other data described that might be required to execute the techniques presented herein.

[0099] Still referring to FIG. 16, the network processor unit(s) 1310 provides a two-way data communication coupling to a network, such as a local area network (LAN) or the Internet. The two-way data communication coupling provided by the network processor unit(s) 1310 can be wired (e.g., via I / O interface(s) 1312, such as an Ethernet hub) or wireless. Meanwhile, I / O interface(s) 1314 may allow for input and output of data with other devices that may be connected to the computing device 1300. For example, the I / O interface 1314 (e g., a universal serial bus hub), may provide a connection to external devices such as a keyboard, keypad, a touch screen, and / or some other suitable input device. External devices can also include portable computer-readable storage media such as database systems, thumb drives, portable optical or magnetic disks, and memory cards.

[0100] Each example embodiment disclosed herein has been included to present one or more different features. However, all disclosed example embodiments are designed to work together as part of a single larger system or method. This disclosure explicitly envisions compound embodiments that combine multiple previously-discussed features in different example embodiments into a single system or method.

[0101] While the disclosure has been illustrated and described in detail and with reference to specific embodiments thereof, it is nevertheless not intended to be limited to the details shown, since it will be apparent that various modifications and structural changes may be made therein without departing from the scope of the disclosure and within the scope and range of equivalents of the claims. In addition, various features from one of the embodiments may be incorporated into another of the embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure as set forth in the following claims.

[0102] It is also to be understood that the elements described herein, or portions thereof, may be fabricated from any suitable material or combination of materials, such as plastic, foamed plastic, metal, supple natural or synthetic materials including, but not limited to, elastomers, polyester, plastic, rubber, derivatives thereof, and combinations thereof. Suitable plastics may include high-density polyethylene (HDPE), low-density polyethylene (LDPE), polystyrene, acry lonitrile butadiene styrene (ABS), polycarbonate, polyethylene terephthalate (PET), polypropylene, ethylene-vinyl acetate (EVA), or the like. Suitable foamed plastics may include expanded or extruded polystyrene, expanded or extruded polypropylene, EVA foam, derivatives thereof, and combinations thereof.

[0103] Reference may be made to the spatial relationships between various components and to the spatial orientation of various aspects of components as depicted in the attached drawings. However, as will be recognized by those skilled in the art after a complete reading of the present disclosure, the devices, components, members, apparatuses, etc. described herein may be positioned in any desired orientation. Thus, the use of terms such as “above,” “below,” “upper.” “lower,” “top,” “bottom,” or other similar terms to describe a spatial relationship between various components or to describe the spatial orientation of aspects of such components, should be understood to describe a relative relationship between the components or a spatial orientation of aspects of such components, respectively, as the components described herein may be oriented in any desired direction. When used to describe a range of dimensions and / or other characteristics (e.g., time, pressure, temperature, distance, etc.) of an element, operations, conditions, etc., the phrase “between X and Y” represents a range that includes X and Y.

[0104] For example, it is to be understood that terms such as “left,” “right,” “top,” “bottom,” “front,” “rear,” “side,” “height,” “length,” “width,” “upper,” “lower,” “interior,” “exterior,” “inner,” “outer” and the like as may be used herein, merely describe points of reference and do not limit the present invention to any particular orientation or configuration. Further, the term “exemplary” is used herein to describe an example or illustration. Any embodiment described herein as exemplary is not to be construed as a preferred or advantageous embodiment, but rather as one example or illustration of a possible embodiment.

[0105] Further, the present disclosure may repeat reference numerals and / or letters in the various examples. This repetition is for the purpose of simplicity' and clarity' and does not in itself dictate a relationship between the various embodiments and / or configurations discussed.

[0106] Similarly, when used herein, the term “comprises” and its derivations (such as “comprising.” etc.) should not be understood in an excluding sense, that is. these terms should not be interpreted as excluding the possibility' that what is described and defined may include further elements, steps, etc. Meanwhile, when used herein, the term “approximately” and terms of its family (such as “approximate,” etc.) should be understood as indicating values very' near to those which accompany the aforementioned term. That is to say, a deviation within reasonable limits from an exact value should be accepted, because a skilled person in the art will understand that such a deviation from the values indicated is inevitable due to measurement inaccuracies, etc. The same applies to the terms “about” and “around” and “substantially.”

[0107] As used herein, unless expressly stated to the contrary', use of the phrase "at least one of,” "‘one or more of,” “and / or,” variations thereof, or the like are open-ended expressions that are both conjunctive and disjunctive in operation for any and all possible combination of the associated listed items. For example, each of the expressions “at least one of X, Y and Z,” “at least one of X, Y or Z,” “one or more of X, Y and Z,” “one or more of X, Y or Z” and “X, Y and / or Z” can mean any of the following: 1) X, but not Y and not Z; 2) Y, but not X and not Z; 3) Z, but not X and not Y: 4) X and Y, but not Z; 5) X and Z. but not Y; 6) Y and Z. but not X; or 7) X, Y, and Z.

[0108] Additionally, unless expressly stated to the contrary, the terms “first,” “second,” “third,” etc., are intended to distinguish the particular nouns they modify (e.g., element, condition, node, outlet, inlet, valve, module, activity', operation, etc.). Unless expressly stated to the contrary, the use of these terms is not intended to indicate any type of order, rank, importance, temporal sequence, or hierarchy of the modified noun. For example, “first X” and “second X” are intended to designate two “X” elements that are not necessarily^ limited by any order, rank, importance, temporal sequence, or hierarchy of the two elements. Further as referred to herein, “at least one of’ and “one or more of’ can be represented using the “(s)” nomenclature (e.g., one or more element(s)).

Claims

CLAIMS1. An orbital welder, comprising: a first module; a second module coupled to the first module at a pivot, wherein the first module and the second module are configured to rotate relative to one another about the pivot, and the first module and the second module cooperatively define a space configured to receive a circular workpiece; a weldhead assembly configured to perform a welding process on the circular workpiece; and a motor disposed in one of the first module or the second module, wherein the motor is configured to drive movement of the weldhead assembly relative to the circular workpiece.

2. The orbital welder of claim 1 , comprising a link configured to couple to the first module and the second module to secure the first module and the second module to the circular workpiece.

3. The orbital welder of claim 2, wherein the link comprises: respective ends coupled to the first module and to the second module; and an adjustment mechanism configured to adjust a force imparted by the link at the respective ends to fix the first module and the second module to one another.

4. The orbital welder of claim 1, comprising: a guide assembly configured to couple to and be disposed around the circular workpiece; and a wheel coupled to the first module or the second module and configured to engage the guide assembly, wherein the wheel is configured to rotate to drive movement of the first module, the second module, the weldhead assembly, and the motor around the circular workpiece.

5. The orbital welder of claim 4, wherein the motor is configured to drive rotation of the wheel.

6. The orbital welder of claim 1 , wherein the motor is configured to drive movement of the weldhead assembly toward and away from the circular workpiece.

7. The orbital welder of claim 1, wherein the circular workpiece extends along an axis, and the motor is configured to drive movement of the weldhead assembly relative to the second module and relative to the circular workpiece along the axis.

8. An orbital welder, comprising: a first module housing; a second module housing pivotably coupled to the first module housing; a weldhead assembly configured to perform a welding process on a workpiece; a linkage coupling the weldhead assembly to the second module housing; and a motor disposed in the second module housing, wherein the motor is configured to move the linkage to drive movement of the weldhead assembly relative to the second module housing and relative to the workpiece.

9. The orbital welder of claim 8, wherein the workpiece extends along an axis, and the motor is configured to move the linkage to drive movement of the weldhead assembly relative to the second module housing and relative to the workpiece along the axis.

10. The orbital welder of claim 8, wherein the motor is configured to move the linkage to drive movement of the weldhead assembly toward and away from the workpiece.

11. The orbital welder of claim 8, comprising: a guide assembly configured to couple to and be disposed around the workpiece; a wheel configured to engage the guide assembly, wherein the wheel is configured to rotate to drive movement of the first module housing, the second module housing, and the weldhead assembly around the workpiece; and an additional motor configured to rotate the wheel.

12. The orbital welder of claim 11, wherein the wheel is rotatably coupled to the first module housing, and the additional motor is disposed in the first module housing.

13. An orbital welder, comprising:a first module; a second module coupled to the first module, wherein the first module and the second module are configured to rotate relative to one another about a rotational axis; a weldhead assembly coupled to the second module and configured to perform a welding process on a workpiece; a first motor configured to actuate a linkage to drive movement of the weldhead assembly relative to the second module to move the weldhead assembly toward and away from the workpiece; and a second motor configured to actuate the linkage to drive movement of the weldhead assembly relative to the second module to move the weldhead assembly relative to the second module along the rotational axis.

14. The orbital welder of claim 13, comprising: a first sensor configured to monitor a distance between the workpiece and the weldhead assembly; and a second sensor configured to monitor movement of the weldhead assembly along the rotational axis.

15. The orbital welder of claim 13, comprising: a guide assembly configured to couple to and be disposed around the workpiece; and a wheel configured to engage the guide assembly, wherein the wheel is configured to rotate to drive movement of the first module, the second module, and the weldhead assembly around the workpiece.

16. The orbital welder of claim 15, wherein the first module and the second module cooperatively define a space configured to receive the workpiece, and the orbital welder comprises an adjustment element configured to move the wheel into and out of the space to adjust a clearance between the workpiece and the first module and the second module.

17. The orbital welder of claim 15, comprising a third motor configured to drive the wheel to rotate.

18. The orbital welder of claim 13, wherein the weldhead assembly comprises: a base coupled to the second module via the linkage;a torch coupled to the base, wherein the torch is configured to generate an arc to perform the welding process on the workpiece; and an imaging device coupled to the base and oriented to capture image data associated with operation of the torch.

19. The orbital welder of claim 18, wherein the weldhead assembly comprises a gas cup coupled to the base and configured to direct gas to facilitate generation of the arc via the torch, the torch extends from the gas cup, the gas cup comprises a groove, and the imaging device is oriented to face the torch through the groove.

20. The orbital welder of claim 18, wherein the weldhead assembly comprises an additional imaging device disposed opposite the imaging device and oriented to capture additional image data associated with the operation of the torch.

Images