Mobile Hardbanding Unit With Switchable PTA and MIG Welding

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Solution Overview

Problem

Existing mobile hardbanding units are limited to certain types of welding, such as MIG and TIG, and do not utilize the more effective PTA welding process, which is easily automated and provides a precise application of the deposited material.

Innovation Solution

A mobile hardbanding system that incorporates PTA welding, allowing for the alternate use of PTA and MIG welding, with separate electrical, gas, and cooling conduits for each torch to simplify switching between processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If PTA welding is used instead of MIG/TIG welding, then manufacturing precision and productivity are improved, but device complexity increases due to separate conduits required for each torch type

Engineering Contradiction:

Improveprecision of deposited material applicationVSAvoidcomplexity of electrical, gas, and cooling conduits

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The mobile hardbanding unit divides the welding system into separate, independent conduit sets for PTA and MIG torches. Each torch type has its own dedicated electrical, gas, and cooling conduits, allowing the system to switch between welding processes without interference while maintaining high precision PTA welding capability when needed.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If the unit is designed to accommodate multiple welding processes (PTA and MIG), then adaptability is improved, but ease of operation deteriorates due to the complexity of switching between processes

Engineering Contradiction:

Improveability to use different welding processesVSAvoidease of switching between welding processes

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

The mobile hardbanding unit incorporates universal support capabilities for both PTA and MIG welding processes within a single device. The unit includes separate but parallel conduit systems that allow operators to select and switch between welding processes based on specific application requirements, making the equipment adaptable to different welding needs while maintaining operational simplicity through standardized interfaces.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 hardbanding of drill string sections using PTA welding, extending the lifetime of drill pipes and collars by reducing frictional wear and improving structural strength, while also providing the versatility of MIG welding.

Implementation Method 1

The unit (10) comprises a PTA welding assembly

Methodology Applied

Scientific EffectPlasma transferred arc welding: Welding

Implementation Method 2

The unit (10) comprises a MIG welding assembly

Methodology Applied

Scientific EffectMIG welding: Welding

Data Source

PatentUS12214449B2Mobile hardbanding unit

Publication Date: 2025.02.04 ACQUAYE JAMES G

AI summary

A mobile hardbanding system that uses PTA welding to perform hardbanding on drill string sections at the well site. The inventive system allows alternate use of PTA and MIG welding. Both a PTA torch and a MIG torch are provided. Changing from one type of welding to the other is simplified by including separate electrical, gas, and cooling conduits for each torch. The torch not in use is parked in the welding compartment near the weld box. The powder hopper for the PTA welding assembly may be mounted on a swivel arm so that it can be moved out of the way when the MIG torch is in use.