Flexible Pipe Welding via Intermediary Ledge Structure
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Solution Overview
Problem
The challenge lies in welding flexible stainless steel pipes with thin thickness differences, which requires complex processes, high costs, and is prone to cracks and corrosion due to thermal stress, especially when connecting structures with skilled operators and separate welding processes are necessary.
Innovation Solution
A flexible pipe connecting structure with a ledge and a filler metal application method, where the filler metal is applied on ridges and valleys, and the pipe is inserted into the connecting structure, allowing for simultaneous heat treatment and welding, preventing filler metal flow and reducing thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If arc welding or plasma welding is used to connect the flexible pipe to the connecting structure, then welding strength can be achieved, but the welding process becomes complicated and costs increase due to the thickness difference between the thin flexible pipe (0.3 mm or less) and the thick connecting structure (1 mm or more)
Solution Approach 1:
A welding ring with intermediate thickness (0.5 mm or more) is introduced as a mediator between the thin flexible pipe and the thick connecting structure. The welding ring is first welded to the flexible pipe by arc welding or plasma welding, then welded to the connecting structure, enabling the connection without requiring complex welding processes for direct thin-to-thick welding
2Strength
If arc welding or plasma welding is used to connect the flexible pipe to the connecting structure, then welding strength can be achieved, but cracks and corrosion occur at the welded bead zones and heat affected zones due to welding stress
Solution Approach 1:
The welding ring serves as a stress-absorbing intermediary that reduces welding stress on the thin flexible pipe. By distributing the welding stress across the intermediate welding ring rather than directly on the thin pipe wall, the occurrence of cracks and corrosion in the heat affected zones is reduced
Solution Approach 2:
The invention changes the thickness parameter of the welding ring to be 0.5 mm or more, which is thicker than the flexible pipe but thinner than the connecting structure. This parameter adjustment allows the welding ring to absorb welding stress while maintaining structural integrity, thereby preventing cracks and corrosion
3Ease of manufacture
If brazing welding method is used to connect the flexible pipe to the connecting structure, then welding can be performed, but it requires a skilled welding operator and cannot be performed by a less skilled operator
Solution Approach 1:
The welding process is segmented into two separate welding operations: first welding the welding ring to the flexible pipe, then welding the welding ring to the connecting structure. This segmentation allows each welding operation to be optimized independently, making the overall process more manageable and less dependent on highly skilled operators
4Ease of manufacture
If a separate welding ring is used to connect the flexible pipe to the connecting structure, then welding becomes easier and cracks/corrosion are reduced, but the device complexity increases
Solution Approach 1:
The connecting structure is designed with a multi-functional integrating portion that combines the functions of the connecting structure and the welding ring into a single component. This integrating portion has a thickness of 0.5 mm or more and can be directly welded to the flexible pipe, eliminating the need for a separate welding ring while maintaining the welding advantages
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 method enables welding by unskilled personnel, reduces manufacturing costs, prevents corrosion, and enhances welding strength by evenly distributing heat, allowing for flexible pipe connections of any length without a separate welding ring.
Implementation Method 1
heating at least a part of the flexible pipe inserted into the flexible pipe connecting structure so that the first end portion of the flexible pipe is welded to the flexible pipe connecting structure by the filler metal
Implementation Method 2
heating at least a part of the flexible pipe inserted into the flexible pipe connecting structure so that the first end portion of the flexible pipe is welded to the flexible pipe connecting structure by the filler metal
Data Source
AI summary
The flexible pipe connected with the flexible pipe connecting structure according to an embodiment of the present invention, wherein the connecting structure includes a body part, and a connecting part configured to have a smaller thickness than a thickness of the body part, wherein the first end portion is inserted into and welded to the connecting part, wherein the ledge is a step part provided between the body part and the connecting part. Also, a method of connecting a flexible pipe connecting structure with a flexible pipe according to an embodiment of the present invention, comprises a filler metal applying step of applying a filler metal on at least one of a first end portion of the flexible pipe having ridges and valleys and a connecting part of the flexible pipe connecting structure into which the first end portion is inserted, a flexible pipe inserting step of inserting the first end portion of the flexible pipe into the connecting part of the flexible pipe connecting structure so that the first end portion is held by a ledge formed on the flexible pipe connecting structure, and a flexible pipe welding step of heating at least a part of the flexible pipe inserted into the flexible pipe connecting structure so that the first end portion of the flexible pipe is welded to the flexible pipe connecting structure by the filler metal.