Cladding Tool Path Segmentation for Large Vessel Surface Coverage
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Solution Overview
Problem
Large pressure vessels present challenges in applying a uniform cladding layer due to their size and geometry, as existing welding methods struggle with reaching all areas and accommodating manufacturing inconsistencies, leading to missed spots or overlaps.
Innovation Solution
A method involving a 3-dimensional model of the component to generate a point distribution and tessellated segments based on the cladding tool's reach, followed by adjusting the tool path in real-time to match the deposited bead dimensions, ensuring a continuous and uniform cladding layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a pre-determined weld path is applied assuming nominal dimensions, then the cladding process can proceed efficiently, but manufacturing variations result in missed areas or overlaps requiring manual rework
Solution Approach 1:
The system performs preliminary 3D scanning and modeling of the component surface before cladding to capture actual geometry deviations from nominal dimensions. This preliminary action enables the generation of an adjusted tool path that anticipates and compensates for manufacturing variations, eliminating the need for manual rework while maintaining process efficiency
Solution Approach 2:
The system uses 3D scanning technology to capture real-time feedback on the actual component geometry and compares it with the nominal model. This feedback loop enables dynamic adjustment of the tool path to match the actual surface features, ensuring complete coverage without overlaps while maintaining efficient automated operation
2Manufacturing precision
If the cladding tool maximum reach is less than the surface size, then the tool can maintain precision and control, but the tool cannot reach all areas of large surfaces in a single pass
Solution Approach 1:
The system divides the large surface into multiple manageable sections or zones based on the cladding tool's maximum reach. Each section is processed independently with optimized tool paths, ensuring precision and control within each segment while collectively covering the entire large surface area through systematic progression between segments
3Adaptability or versatility
If the component geometry differs from nominal design due to manufacturing variability, then the actual part reflects real-world conditions, but pre-determined tool paths based on nominal dimensions result in missed areas or overlaps
Solution Approach 1:
The system transitions from static pre-determined tool paths based on nominal dimensions to dynamic tool paths that adapt in real-time to the actual component geometry. The 3D scanning data captures manufacturing variations, and the control system dynamically adjusts tool positions, speeds, and trajectories to maintain precise cladding coverage on the actual part geometry
Solution Approach 2:
The system modifies tool path parameters such as position coordinates, travel speed, and deposition rate based on actual measured geometry deviations. By changing these parameters dynamically according to real surface conditions rather than relying on nominal values, the system achieves accurate cladding coverage that adapts to manufacturing variations
Data Source
AI summary
A method and apparatus for applying a cladding layer to a surface of a component uses a cladding tool having a maximum reach less than the size of the surface. Geometry of the surface is segmented into a plurality of tessellated segments, each of which has a peripheral extent determined by a maximum reach of the cladding tool. A nominal tool subpath for each tessellated segment is generated, and then combined to generate a nominal tool path for depositing the cladding layer on the surface. The surface is clad using the nominal toolpath, including a process of adjusting the nominal tool path to an adjusted tool path that accounts for dimensions of the bead to be deposited by the tool to match an edge of the bead to be deposited with an edge of a previously deposited bead.