Flexible Welding Guide With Sensor Indicators
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Solution Overview
Problem
Current guide devices for welding pipelines lack automation in determining the precise location of welding layers, leading to inefficiencies and slowed processes, especially in multi-station welding scenarios like those at sea.
Innovation Solution
A flexible guide device with a pattern of indicators, such as holes, along its length, which can be detected by a sensor and processed to determine the exact position, allowing for automated location determination and precise alignment for subsequent welding steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual location indication methods (e.g., chalk markers) are used to mark welding layer positions, then the process can be completed with simple equipment, but the welding process speed decreases and automation is impeded
Solution Approach 1:
The patent replaces manual mechanical location marking methods (chalk indicators) with an automated optical/electronic detection system. Sensors detect the position of welding layers by reading markings on the pipe surface, and this position information is automatically transmitted to subsequent welding stations, eliminating manual search and marking operations.
Solution Approach 2:
The patent creates a positional copy of the welding layer location by detecting the position of the welding layer and transmitting this position information to the next welding station. This allows the subsequent station to automatically locate and continue welding from the correct position without manual intervention.
2Loss of time
If operators manually search for welding layer locations between stations, then equipment complexity remains low, but time is lost and efficiency decreases
Solution Approach 1:
The patent performs preliminary action by marking the position of the welding layer during the current welding operation. These position markings remain on the pipe surface and serve as pre-prepared location references for subsequent welding stations, eliminating the need for time-consuming manual searches.
Solution Approach 2:
The patent implements a feedback system where the position of the welding layer is detected by sensors and this position information is fed back to subsequent welding stations. This closed-loop information flow ensures that each station can automatically locate and continue from the correct position without manual intervention.
3Measurement precision
If automated sensor detection systems are implemented to detect indicator patterns, then location determination precision improves, but device complexity increases
Solution Approach 1:
The patent uses visual markers or indicators with distinct patterns (referred to as 'color changes' in the broader sense of visual differentiation) on the pipe surface that can be easily detected by sensors. These indicators provide high-contrast, easily distinguishable signals that simplify the detection process while maintaining high positioning accuracy.
Data Source
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AI summary
Guide device (3) for use in the processing, in particular welding, of curved surfaces, in particular pipe surfaces, comprising a flexible elongate body (3) provided with a guide for processing means; tensioning means (4) for tensioning the flexible body around the curved surface; wherein the flexible body is provided along its length with indicators (8,8') arranged according to a determined pattern, this pattern being such that a determined position along the flexible body can be inferred on the basis of the detection of the indicators. The elongate flexible body is further provided on its underside with spacers (7) with spring means wherein the width and length dimensions of the contact surface between each spacer and the curved surface are small relative to the width and length dimensions of the guide band.