Automated Electroslag Welding for Beam-to-Column Moment Connections
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Solution Overview
Problem
The existing welding processes for erecting high-rise buildings, such as multipass gasless flux-core and gas shielded flux-core wire welding, are laborious and time-consuming for creating strong beam-to-column moment connections, which hinders the speed of construction.
Innovation Solution
An automated Electroslag welding system and method that uses a mechanized assembly to weld doubler plates to vertical and horizontal beam webs, employing a consumable guide tube and VertaSlag™ welding process to create a strong, fast, and efficient beam-to-column moment connection, applicable to various welding techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multipass gasless flux-core or gas shielded flux-core wire welding is used to create beam-to-column moment connections, then the connection strength is sufficient, but the welding process becomes laborious and time-consuming
Solution Approach 1:
The welding process is divided into multiple passes with each pass depositing a portion of the total weld metal. The first pass creates a root weld, subsequent passes build up the weld profile, and final passes complete the connection. This segmentation allows for controlled deposition of weld metal while maintaining connection strength requirements.
Solution Approach 2:
Before the actual welding process, the workpieces are positioned and clamped in a fixture that pre-establishes the correct geometry and alignment. The fixture includes support surfaces and positioning elements that prepare the joint configuration in advance, eliminating the need for complex alignment operations during welding.
2Productivity
If automated welding systems are implemented to reduce welding time, then productivity increases, but device complexity increases
Solution Approach 1:
The welding system incorporates automatic wire feeding mechanisms that continuously supply welding wire to the torch without manual intervention. The system also includes automatic torch oscillation control and parameter adjustment capabilities, allowing the welding process to proceed autonomously once initiated, thereby reducing operator workload while maintaining high productivity.
Solution Approach 2:
The welding fixture is designed with universal features that can accommodate different beam and column configurations. The fixture includes adjustable clamps and positioning elements that can be reconfigured for various joint types and sizes, allowing a single fixture design to serve multiple welding applications without requiring custom tooling for each configuration.
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
The automated system significantly reduces welding time and strengthens the beam-to-column flange weld connection, facilitating faster construction of both low-rise and high-rise buildings by automating the welding process and ensuring high-quality welds.
Implementation Method 1
The consumable guide tube and the welding wire carry the welding current to the molten weld puddle at the bottom of the weld cavity
Implementation Method 2
automated vertical moment connection welding using a mechanized assembly and the VertaSlag™ welding process
Data Source
AI summary
An automated assembly, system and method for a narrow-gap Electroslag-welded moment connection welded between horizontal beam to vertical column flanges includes vertical column doubler plates affixed to the column web and horizontal beam doubler plates affixed to the beam web with alignment of the respective webs/doubler plates to carry the moment load through the vertical support columns. An embodiment includes a radius in each horizontal beam doubler plate. The assembly, system and method are readily applicable to overdesign moment load factors.