Chain-Driven Pipe Welding Head for Short Pipe Automation
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Solution Overview
Problem
Conventional automatic welding of pipes with flanges is inefficient due to the difficulty in seating shorter pipes on guide rollers, requiring manual welding and skilled labor, leading to longer construction times and higher costs.
Innovation Solution
An automatic welding system with a rotatable welding head and chain-driven mechanism that allows precise positioning and control of a welding machine along the pipe's circumference, converting analog voltage values to digital for precise control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional guide rollers are used for automatic welding, then welding automation is achieved, but pipes shorter than the gap between guide rollers cannot be seated and welded automatically
Solution Approach 1:
The patent introduces a chain-driven welding head as an intermediary mechanism between the pipe and the welding torch. The welding head travels along the chain that wraps around the pipe, enabling the welding system to accommodate pipes of various lengths without requiring the pipe to be seated on fixed guide rollers. This intermediary mechanism resolves the contradiction by decoupling the welding automation from the pipe seating constraint.
2Adaptability or versatility
If manual welding is used for short pipes, then welding can be performed on any pipe length, but production time increases significantly to 1-2 hours per weld
Solution Approach 1:
The welding head is designed to be self-propelled along the chain, automatically positioning itself for welding without requiring manual repositioning or intervention. The system performs the welding operation autonomously as the welding head travels around the pipe, maintaining high productivity while achieving universal applicability to all pipe lengths.
3Manufacturing precision
If skilled workers perform manual welding, then welding quality can be maintained, but labor costs and construction time increase
Solution Approach 1:
The patent replaces the manual mechanical welding process with an automated welding head that travels along the pipe. The automated system maintains consistent welding quality through precise control mechanisms while eliminating the time loss associated with skilled worker intervention and manual positioning.
4Ease of manufacture
If analog welding machine control is used, then existing welding machines can operate, but precise control and real-time monitoring are difficult to achieve
Solution Approach 1:
The patent implements a parameter conversion system that transforms analog control signals from the welding machine into digital values for precise measurement and control. The controller converts analog voltage values to digital signals, enabling precise monitoring and adjustment of welding parameters while maintaining compatibility with existing analog welding machines.
Data Source
AI summary
An automatic welding system for a pipe wherein an automatic welding head is rotatably installed on a pipe and welding is performed with a welding machine, and a chain is wound around and thereby installed on the pipe, the automatic welding head is rotatably installed along the chain, the chain is movably passed through openings formed on both sides of the automatic welding head, the chain is guided by a guide roller while being wound around a gear driven to rotate by a driving motor provided in the automatic welding head, and the pipe is precisely welded using the welding machine which is adjusted in position by a position adjustment unit of the automatic welding head under the control of a control device while wheels provided in the automatic welding head rotate along the pipe.