Magnetic Flux Weld Seam Tracking for Tubular Marking
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Solution Overview
Problem
Existing systems fail to accurately and efficiently locate and mark the longitudinal weld seam in longitudinally welded tubulars, particularly in the oil and gas industry, due to positional changes caused by tubular rotation or weld seam twisting, which hinders efficient ultrasonic inspection and production.
Innovation Solution
A system comprising a longitudinal weld seam detection assembly and a marking assembly, utilizing magnetic flux generators and sensors to detect and mark the weld seam, with a computer-controlled mechanism to adjust the marking assembly's position and apply marks on the tubular surface, accommodating varying diameters and seam positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If magnetic flux generators and sensors are used to detect weld seam position, then measurement precision of weld seam location is improved, but device complexity increases due to additional detection and control systems
Solution Approach 1:
The detection system is divided into multiple magnetic flux generators and sensors positioned at different locations around the tubular. Each sensor independently detects weld seam position, and the computer processes signals from multiple sources to determine accurate location, achieving high precision through distributed measurement points
Solution Approach 2:
Magnetic flux generators create an intermediate magnetic field that interacts with the weld seam to produce detectable signals. The sensors detect changes in this magnetic field caused by the weld seam's presence and position, using the magnetic field as an intermediary to indirectly measure weld location with high precision
2Manufacturing precision
If the marking assembly is continuously adjusted to track weld seam position changes, then manufacturing precision of weld seam marking is improved, but productivity decreases due to additional adjustment time
Solution Approach 1:
The computer calculates the required marking assembly position in advance based on detected weld seam location, and the marking assembly is quickly repositioned to the predetermined location before marking occurs. This preliminary calculation and positioning approach minimizes adjustment time while ensuring accurate marking placement
Solution Approach 2:
The manual or mechanical adjustment system is replaced with a computer-controlled positioning system that automatically adjusts the marking assembly position based on electronic signals from sensors. This substitution enables rapid, precise positioning without manual intervention, maintaining high marking accuracy while increasing production speed
3Ease of manufacture
If the tubular rotates during welding and inspection, then ease of manufacture is improved, but measurement precision of weld seam position deteriorates due to position changes
Solution Approach 1:
The detection system is designed to dynamically track weld seam position changes during tubular rotation. Sensors continuously monitor magnetic field variations as the tubular rotates, and the computer processes these changing signals in real-time to maintain accurate weld seam location measurement throughout the rotation process
Solution Approach 2:
The system uses feedback from magnetic sensors that continuously detect weld seam position during rotation. The computer receives real-time position information and adjusts tracking accordingly, creating a closed-loop system that maintains measurement precision despite the dynamic rotating conditions during manufacturing
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 precise and continuous tracking of the weld seam, allowing for efficient ultrasonic inspection and increased production by ensuring accurate marking of the weld seam, thereby improving manufacturing efficiency.
Implementation Method 1
a magnetic flux generator for generating a magnetic field through the tubular
Implementation Method 2
Weld seams in the tubular cause discontinuities in the magnetic flux lines which are generated in the tubular. These discontinuities in the magnetic field are detected by the sensing elements.
Implementation Method 3
use eddy current of suitable frequency for this purpose. Eddy current is sounded into a longitudinally welded tubular by means of a probe and the received signal is converted into a display which results either in a low signal (base material) or in a high signal (weld)
Data Source
AI summary
Longitudinally welded tubular member inspection and marking systems and methods. One system includes a longitudinal weld seam detection assembly and a marking assembly configured to be positioned about a longitudinally welded tubular member in an inspection position. The detection assembly includes a magnetic flux generator including a flux return and one or more sensors supported by the flux return and sensor supports. The marking assembly includes one or more marking heads. A computer is programmed to accept longitudinal weld seam detection signals transmitted from the one or more sensors and convert them into positioning information for the marking assembly to mark the longitudinal weld seam.