Internal Pipe Welding Head Positioning Under Cantilever Deflection
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Solution Overview
Problem
Existing internal welding devices face issues with cantilever arm deflection and rotation due to magnetic fields and heat, affecting weld seam quality and geometry.
Innovation Solution
A control device with lasers and cameras attached to the suspension and welding head, respectively, to detect and correct deviations in the cantilever arm's position, ensuring precise welding head positioning through a closed control loop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a long cantilever arm is used to reach into the pipe for welding, then the welding head can access the welding area, but the cantilever arm deflects and rotates due to magnetic fields and heat, affecting welding precision
Solution Approach 1:
The patent implements a feedback control system using lasers attached to the suspension and cameras attached to the welding head. The lasers project reference patterns that the cameras detect, allowing real-time measurement of cantilever deflection and rotation. The control device uses this feedback to calculate compensation values and adjust the welding head position, closing the control loop to maintain welding precision despite cantilever deformation
Solution Approach 2:
The patent replaces mechanical position measurement and adjustment mechanisms with an optical measurement system (lasers and cameras) combined with computational control. Instead of using complex mechanical sensors and actuators to directly measure and correct cantilever position, the system uses optical fields to detect deflection and computational algorithms to generate correction signals, reducing mechanical complexity while improving measurement precision
2Ease of operation
If welding media are transported through the cantilever to the welding head, then welding can be performed, but high temperatures cause additional bending and rotation of the cantilever
Solution Approach 1:
The optical measurement system continuously monitors cantilever position changes caused by temperature-induced thermal expansion and bending. The feedback control calculates compensation based on real-time deflection measurements, allowing the system to maintain welding precision even as the cantilever geometry changes due to heat from welding operations and media transport
Solution Approach 2:
The system dynamically adjusts welding head position parameters based on real-time feedback about thermal deformation. By continuously monitoring and compensating for temperature-induced changes in cantilever geometry, the system adapts to varying thermal conditions during welding operations, maintaining position accuracy despite changing temperature parameters
3Productivity
If the welding head is positioned at the end of the cantilever arm, then internal welding can be performed, but magnetic fields deflect and rotate the cantilever arm affecting weld seam quality
Solution Approach 1:
The patent employs real-time feedback control where cameras mounted on the welding head detect laser reference patterns to measure cantilever deflection and rotation caused by magnetic fields. The control device processes this information and generates compensation signals to adjust welding head position, maintaining weld seam quality and geometry despite magnetic field interference during internal welding operations
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
Improves weld seam quality and reproducibility by reducing errors such as seam alignment and undercut, enhancing the precision and consistency of the welding process.
Implementation Method 1
one or more lasers (5) are attached to the suspension (3), wherein one or more laser beams (5a) are respectively directed onto, and recognizable by the one or more cameras (6)
Implementation Method 2
one or more cameras (6) are attached to the welding head (4), wherein one or more laser beams (5a) are respectively directed onto, and recognizable by the one or more cameras (6)
Implementation Method 3
a control device for moving the welding head, one or more lasers are attached to the suspension, one or more cameras are attached to the welding head, wherein one or more laser beams are respectively directed onto, and recognizable by the one or more cameras
Data Source
AI summary
The invention relates to a device (1) for the internal welding of pipes and profiles, comprising a cantilever arm (2, 2a), which is secured to a suspension (3), which cantilever arm can be inserted into the pipe or profile to be welded and on which a welding head (4) is displaceably attached, the cantilever arm (2, 2a) further comprising at least one laser (5) and at least one camera (6). To avoid the disadvantageous effects of magnetism and heat on the position of the welding head (4), the invention proposes that a laser (5) is attached on the suspension (3), and a camera (6) for observing the laser beam (5a) is attached on the end of the cantilever arm (3) or on the welding head (4). A correction signal is calculated from the change in position of the laser beam (5a) observed with the camera (6) and forwarded to a control unit for adjusting the welding head (4) by means of displacement devices (8, 9).