Automated Hardfacing of Roller Cones Using Oscillating Plasma Torch
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for applying hardfacing to roller cones in drill bits are inefficient due to manual labor dependency, inconsistent quality, and limitations in robotic automation, including unsatisfactory robotic torch performance, inability to identify and correct for varying designs, and access issues with complex surfaces.
Innovation Solution
A system and method utilizing a vertically oriented plasma transfer arc torch secured to a positioner with controllable movement, combined with a robotic arm to oscillate the torch and move the roller cone, allowing for precise hardfacing patterns and automated correction for manufacturing variations, improving access to complex surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual hardfacing application methods are used, then skilled labor can apply hardfacing to complex surfaces, but the process is labor-intensive, inconsistent, and costly
Solution Approach 1:
The patent replaces manual mechanical hardfacing application with an automated robotic system that uses a plasma transfer arc torch. The robotic arm positions and moves the torch to apply hardfacing material automatically, eliminating the need for skilled manual labor while maintaining consistent application quality through programmable control.
Solution Approach 2:
The system controls hardfacing application parameters such as torch oscillation amplitude and frequency, travel speed, and plasma arc characteristics through programmable parameters. This allows precise control over the hardfacing process to achieve consistent results that match or exceed manual application quality.
2Extent of automation
If robotic systems are used for hardfacing, then automation is improved, but access to complex surfaces and individual roller cone designs is limited
Solution Approach 1:
The robotic system employs dynamic torch oscillation where the torch moves back and forth in a controlled pattern during hardfacing application. This oscillation motion allows the torch to access and coat complex curved surfaces of roller cones effectively, adapting to the geometry while maintaining automated operation.
Solution Approach 2:
The robotic hardfacing system is designed with universal adaptability to handle different roller cone designs and configurations. Through programmable control and adjustable torch parameters, the same robotic system can accommodate various sizes, shapes, and designs of roller cones without requiring dedicated fixtures or programming for each design.
3Manufacturing precision
If manual hardfacing is used, then individual roller cone designs can be addressed, but production time increases
Solution Approach 1:
The robotic system incorporates feedback mechanisms including vision systems and sensors that automatically detect and identify individual roller cone designs during the hardfacing process. This feedback allows the system to automatically adjust parameters and correct for manufacturing variations without manual intervention, maintaining precision while speeding up production.
Solution Approach 2:
The system performs preliminary identification and characterization of the roller cone design before the hardfacing application begins. This preliminary action allows the control system to pre-load appropriate parameters and settings specific to that design, enabling immediate optimized hardfacing application without trial-and-error adjustments during production.
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
This approach enhances the consistency and quality of hardfacing, reduces reliance on skilled labor, and decreases production time, leading to more reliable and cost-efficient drill bits.
Implementation Method 1
A system using a vertically oriented plasma transfer arc torch secured to a positioner with controllable movement
Implementation Method 2
plasma transfer arc torch...allowing for precise hardfacing patterns
Data Source
AI summary
Methods of depositing hardfacing material portions of earth-boring tools may involve supporting at least a portion of an earth-boring tool in a holder of a workpiece positioner, the holder being movable in at least a third plane. A location of a surface of the at least a portion of the earth-boring tool may be determined utilizing at least one sensor. The workpiece positioner, the sensor, and a torch positioner comprising a hardfacing torch movable in at least a first plane perpendicular to the third plane and a second plane parallel to the third plane may be controlled utilizing a programmable control system to cause the torch positioner to oscillate the hardfacing torch in the second plane while selectively causing the workpiece positioner to move the holder in the third plane and causing the torch to deposit hardfacing material on the surface.