Orbital Welding Device for Steel Pipes Using Segmented Guide Base Plates
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Solution Overview
Problem
Current orbital welding devices for connecting steel pipes are complex, heavy, and inefficient, requiring significant effort for centering and alignment, especially for large diameters, and lack an industrially applicable solution that balances quality and economic efficiency.
Innovation Solution
A device with guide base plates and clamping elements for secure attachment to pipe ends, allowing for orbital movement of welding and testing tools, decoupling centering from final welding, and using a single welding head to achieve a 360° seam, along with laser beam welding and ultrasound testing for quality control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If guide rings are used to guide orbital carriage for welding pipes, then welding can be performed, but the device becomes very heavy and complex requiring elaborate alignment and centering
Solution Approach 1:
The device is divided into separate functional modules: guide base plates that attach to pipe ends, a movable frame carrying welding tools, and clamping elements. This segmentation allows each component to perform its specific function independently, reducing overall complexity while maintaining welding reliability
Solution Approach 2:
Pipe ends are pre-aligned and tack-welded before the orbital welding process begins. The guide base plates are pre-attached to the pipe ends, establishing a stable reference framework before the main welding operation, which simplifies the subsequent welding process
2Manufacturing precision
If guide rings with multiple clamping screws are used for orientation, then pipe positioning is achieved, but the device becomes heavy and difficult to use in mobile applications
Solution Approach 1:
The positioning function is segmented into guide base plates that provide geometric guidance and clamping elements that secure the plates to pipes. This separation allows lightweight construction while maintaining precision alignment capabilities
Solution Approach 2:
Complex mechanical centering mechanisms are replaced by a simpler system where guide base plates are directly attached to pre-aligned pipe ends using clamping elements, eliminating the need for heavy guide rings and elaborate centering devices
3Reliability
If two welding heads offset by 180° are used for 360° welding, then complete circumferential welding is achieved, but the device complexity increases
Solution Approach 1:
Multiple welding functions are merged into a single welding head mounted on the movable frame. The frame itself provides the 360° orbital movement, eliminating the need for multiple offset welding heads while achieving complete circumferential welding
4Stability of the object's composition
If elaborate centering devices with great holding forces are used for large pipe diameters, then geometric stability is ensured, but the device becomes very heavy
Solution Approach 1:
Pipe ends are pre-aligned and tack-welded before the orbital welding process, establishing geometric stability in advance. This eliminates the need for heavy centering devices during the main welding operation
Solution Approach 2:
The centering function is extracted from the main welding device and performed as a separate preliminary operation. Guide base plates are attached to already-centered pipe ends, allowing the welding device itself to remain lightweight
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 device simplifies the construction and operation, reduces time and cost, enhances flexibility for mobile applications, and ensures precise and efficient welding with improved quality control, suitable for various pipe diameters.
Implementation Method 1
laser beam welding, combined laser beam/laser arc welding or electric arc welding
Implementation Method 2
electric arc welding
Implementation Method 3
ultrasound testing for quality control
Data Source
AI summary
A device for connecting the ends of pipes, which are aligned, tack-welded and made of steel, by an orbital welding process using a welding joint formed by the pipe ends and using tools which can be orbitally moved about the welding joint for welding and checking the seam. The device includes guide base plates placed on both sides at each pipe end in the region of the welding joint and rigidly clamped to the pipe ends. The guide base plates centrally have a circular recess with a radial opening for the feed-through of the pipes to be welded. The guide base plates include clamping elements rigidly connected to each guide base plate face facing away from the welding joint, and a frame for receiving the welding and checking tools, the frame rotatably mounted between the guide base plates and centrally pivotal about the pipe ends by at least 360°.