Autonomous Internal Pipe Welding With Multi-Arm Seam Segmentation
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Solution Overview
Problem
Current robotic systems for welding pipes from the inside lack efficiency and precision, particularly in autonomously welding junctions between pipe segments.
Innovation Solution
A system comprising an autonomous guided vehicle equipped with one or more robotic welding arms, each with a welding torch and camera, capable of autonomously welding the internal circumference of seams between pipe segments. The system includes a welding power supply, wire drum, gas cylinder, and a system controller to manage the robotic welding arms and associated equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple robotic welders are mounted on the autonomous guided vehicle to weld different portions of the seam simultaneously, then productivity is improved, but device complexity increases
Solution Approach 1:
The welding system divides the circular seam into multiple segments, with each robotic welder responsible for welding a specific portion (e.g., 180 degrees or 90 degrees) of the seam. This segmentation allows simultaneous welding of multiple portions, effectively doubling or quadrupling the welding speed compared to a single welder, while each individual welder maintains manageable complexity
Solution Approach 2:
Multiple robotic welders, each with their own torch, camera, and control systems, are merged onto a single autonomous guided vehicle platform. The vehicle integrates power supplies, wire drums, gas cylinders, and a central system controller that coordinates all welders, creating a unified multi-functional system that achieves high productivity through coordinated simultaneous operation
2Manufacturing precision
If seven-axis robotic welders with six-axis welding arms are used to achieve precise welding, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system employs seven-axis robotic welders where a six-axis welding arm is mounted on a linear actuator, creating a dynamic 7-degree-of-freedom system. The linear actuator provides the seventh axis of motion, allowing the welding arm to adjust its position and orientation dynamically along the seam, achieving precise welding coverage of complex circular geometries while maintaining system adaptability
Solution Approach 2:
A linear actuator serves as an intermediary component between the autonomous guided vehicle platform and the six-axis welding arm. This intermediary mechanism enables precise control of the welding arm's position and orientation, facilitating accurate welding operations while isolating the complexity of the 7-axis system from the vehicle's main control architecture
3Adaptability or versatility
If orbital welding heads with extensions are used to reach the seam, then adaptability is improved, but device complexity increases
Solution Approach 1:
The system uses extensions with adjustable lengths that can be configured based on the inner diameter of the pipe or tube. By changing the extension length parameter, the orbital welding head can reach the seam in pipes of various diameters, providing adaptability across different applications without requiring completely different welding head designs for each pipe size
4Manufacturing precision
If cameras and image processing are used to control the welding arms, then manufacturing precision is improved, but loss of information increases due to real-time data processing requirements
Solution Approach 1:
Cameras mounted on each robotic welder capture real-time image data of the weld area, which is processed by the system controller to provide feedback on the welding arm's position and the seam's geometry. This feedback loop enables continuous adjustment of the welding parameters and arm positioning, ensuring high welding accuracy while the real-time processing maintains synchronization with the welding operation
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 system enables efficient and precise autonomous welding of pipe segments, reducing the time required to weld each seam by allowing multiple robotic welders to operate simultaneously, while ensuring high-quality welds through real-time image data processing and AI control.
Implementation Method 1
each robotic welding arm having a welding torch
Implementation Method 2
a camera oriented to capture welding image data mounted thereon
Data Source
AI summary
A system for autonomously welding piping or tubing from the inside comprising: an autonomous guided vehicle configured to travel within a pipe or tube; one or more robotic welders mounted on the autonomous guided vehicle, each robotic welder having a welding torch and a camera oriented to capture welding image data mounted thereon, each robotic welder configured to weld a portion of an internal circumference of a seam between adjacent segments of the pipe or tube; a welding power supply, a wire drum, a gas cylinder, and a welding controller connected to each robotic welding arm and mounted on the autonomous guided vehicle; and, a system controller mounted on the autonomous guided vehicle, the system controller operatively connected to control each of the one or more robotic welders and associated welding power supply, wire drum, gas cylinder, and welding controller.