Internal Pipe Branch Welding with Programmable Electrode Motion
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Solution Overview
Problem
Conventional welding devices are inadequate for welding pipe branches and extensions to a main pipe when the inner diameters are small, the junction is disproportionately large, or there are numerous branch pipes, making it impractical to build a closed shielding gas chamber, and these challenges cannot be addressed by conventional orbital welding devices.
Innovation Solution
A device where the electrode is guided longitudinally inside the main pipe, with its rotational axis aligned with the pipe's central axis, allowing axial movement and rotation to create customizable welding patterns, including perpendicular and back-and-forth movements, and a weaving motion to widen the seam, using servo motors to program the electrode shaft's movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional orbital welding devices are used, then welding can be performed on accessible pipe joints, but the devices cannot fit into branch pipes with small inner diameters
Solution Approach 1:
The welding device inverts the conventional approach by positioning the electrode at the end of a long shaft that extends through the pipe interior, rather than approaching from the outside. The electrode shaft passes through the pipe center, allowing welding of branch pipes from the inside of the main pipe, enabling access to locations where conventional external devices cannot fit.
Solution Approach 2:
The invention transitions from external to internal welding by moving the electrode through the longitudinal dimension of the pipe. The electrode shaft extends axially through the pipe, allowing the electrode to reach branch pipe openings from the pipe interior, effectively utilizing the pipe's internal space for welding operations.
2Reliability
If a closed shielding gas chamber is built to protect the welding area, then welding quality is maintained, but the chamber becomes impractically large when there are many branch pipes along the main pipe perimeter
Solution Approach 1:
The shielding gas protection is segmented into individual zones rather than requiring a single large enclosed chamber. Each branch pipe welding location receives localized shielding gas flow directed at the specific welding point, allowing multiple branch pipes to be welded along the main pipe without requiring a encompassing chamber that would be impractically large.
Solution Approach 2:
The patent introduces shielding gas nozzles as intermediary elements that deliver protective gas directly to the welding zone. These nozzles are positioned to direct gas flow onto the branch pipe opening and welding area, creating localized shielding zones without requiring a large enclosing chamber structure.
3Ease of operation
If the electrode is positioned far from the welding surface to accommodate large junctions, then access is easier, but the welding quality deteriorates due to excessive distance
Solution Approach 1:
The electrode shaft is designed to be rotatable and axially movable, allowing dynamic adjustment of the electrode position. The shaft can rotate to orient the electrode perpendicular to branch pipe openings and move axially to maintain optimal welding distance, adapting to different branch pipe locations and sizes while preserving welding quality.
Solution Approach 2:
The electrode shaft performs periodic rotational movements to position the electrode at different angular orientations around the main pipe. This periodic rotation allows the electrode to approach each branch pipe opening at the correct angle and distance, maintaining welding quality across multiple branch pipes with varying geometries.
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
Enables the implementation of diverse welding requirements by allowing precise control over the welding process, including extending pipes, welding flanges, and connecting branch pipes, while maintaining a consistent shielding gas supply without the need for a large shielding gas chamber.
Implementation Method 1
an electrode (5) fastened to the holder, the electric current discharging from the tip of which melts the materials of the parts to be welded together on both sides of the seam line
Implementation Method 2
a frame (30) and a frame cylinder (31)... a welding jig (1, 1.2, 1.3) arranged to support the main pipe (6.1) in the welding station
Implementation Method 3
The rotator disc (13) of the electrode shaft (3), through which the electrode shaft (3) is able to slide axially
Implementation Method 4
The movement shaft (14) is moved by the screw (18) driven by the motor (17)
Data Source
AI summary
A device for welding pipe branches and extensions from inside the main pipe. The device includes a frame, a frame cylinder, an elongated electrode shaft having a longitudinal central axis, a rotator disc through which the electrode shaft is able to slide axially, an end of shaft electrode holder, an electrode fastened to the holder, a welding jig with: a fastening element; a rotating element, which combines the rotational axis of the welding jig with the central axis of the electrode shaft; a main pipe support bracket; and an adapter piece which guides the shielding gas channel, into the main pipe and into the pipe branch or extension to be welded. The rotator disc is equipped with a locking device to immovably lock the electrode shaft in relation to the rotator disc.