Cylindrical Welding System with Multi-Apparatus Rotation
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Solution Overview
Problem
Welding thick-walled cylindrical structures, such as core barrels, faces challenges with weld contraction differences leading to inclination fluctuations between stacked cylindrical components, requiring time-consuming adjustments to maintain precision.
Innovation Solution
A welding system employing multiple welding apparatuses positioned at equal intervals in the circumferential direction, with a moving device to rotate the structures and a control device to manage positional deviations, ensuring continuous rotation and precise welding by arc welding or high-density energy methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is performed by using a filler metal on thick-walled structures, then the welding strength is improved, but weld contraction differences cause inclination fluctuations between stacked cylindrical components
Solution Approach 1:
The welding process is segmented into multiple passes with the welding apparatus performing welding at different positions around the circumferential direction. The cylindrical structure is divided into multiple welding sections, each welded sequentially while rotating the structure, which distributes and controls the weld contraction effects across different segments.
Solution Approach 2:
The welding process employs periodic action by rotating the upper cylindrical structure to a predetermined angle position and performing welding, then repeating this cycle. This periodic rotation and welding approach allows controlled heat input distribution and manages weld contraction effects through repeated cyclic operations.
2Manufacturing precision
If welding is performed at a position separate by a predetermined angle after welding for a predetermined angle to correct inclination, then the inclination precision is improved, but the welding time increases
Solution Approach 1:
The welding process maintains continuity by rotating the upper cylindrical structure and continuously performing welding operations at different angular positions without stopping. The moving device rotates the structure while the welding apparatus continuously deposits filler metal, eliminating idle time between welding positions and maintaining productive action throughout the process.
Solution Approach 2:
The system employs dynamic control by continuously rotating the upper cylindrical structure during welding and adjusting the welding parameters based on real-time conditions. The moving device provides dynamic motion control to maintain optimal welding conditions while correcting inclination through controlled rotation and continuous filler metal deposition.
3Manufacturing precision
If multiple welding apparatuses are disposed at equal arrangement intervals in the circumferential direction, then the welding precision is improved by reducing inclination fluctuations, but the device complexity increases
Solution Approach 1:
Multiple welding apparatuses are merged into a single integrated system with a common control device and moving device. The welding apparatuses are combined with the rotation mechanism and control system to function as a unified welding system, reducing operational complexity while maintaining multiple welding positions for improved precision.
Solution Approach 2:
The moving device serves multiple functions by simultaneously rotating the upper cylindrical structure, positioning it for welding at different angles, and enabling continuous motion during the welding process. The control device also performs multiple functions including monitoring inclination, determining rotation angles, and controlling both the moving device and welding apparatuses.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables efficient and precise welding of cylindrical structures by minimizing inclination fluctuations and reducing the time required for the welding process through continuous rotation and adaptive control of welding conditions.
Implementation Method 1
each of the welding apparatuses has a filler metal and a heating source which melts the filler metal, and is configured to melt and fuse the filler metal on the welding end surfaces
Implementation Method 2
each of the welding apparatuses has a filler metal and a heating source which melts the filler metal, and is configured to melt and fuse the filler metal on the welding end surfaces to thereby weld the welding end surfaces
Data Source
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AI summary
There is provided a welding system and a welding method of cylindrical structures capable of efficiently welding the cylindrical structures with high precision. A welding system of cylindrical structures which welds a welding end surface of an upper cylindrical structure and a welding end surface of a lower cylindrical structure, each of which being an end surface in an axial direction thereof and facing each other, includes: two or more welding apparatuses which are opposite to the welding end surfaces of the upper cylindrical structure and the lower cylindrical structure and are disposed at equal arrangement intervals in the circumferential direction of the cylindrical structures; a moving device which is configured to rotate the upper cylindrical structure and the lower cylindrical structure relative to the welding apparatuses in a circumferential direction of the cylindrical structures; and a control device which is configured to control operations of the welding apparatuses and the moving device, wherein each of the welding apparatuses has a filler metal and a heating source which melts the filler metal, and is configured to melt and fuse the filler metal on the welding end surfaces to thereby weld the welding end surfaces, and the control device is further configured to continuously rotate the upper cylindrical structure and the lower cylindrical structure by an angle of the arrangement interval of the welding apparatuses by the moving device, while welding the welding end surfaces with the welding apparatuses.