Prestressed Tubular Pile Welding with Laser Seam Detection
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Solution Overview
Problem
The manual gas shielded welding method for prestressed tubular piles is prone to fatigue and quality inconsistencies due to operator variability, leading to inefficiencies and challenges in maintaining standard operation and ensuring consistent construction quality.
Innovation Solution
An automatic welding method and device that includes a welding seam detecting module to determine the position of the target welding seam and a welding module to perform precise welding around the prestressed tubular piles, utilizing intelligent welding robots and laser measuring instruments to ensure accurate and efficient seam welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual gas shielded welding method is used, then welding operation can be performed, but welding quality is inconsistent and difficult to control
Solution Approach 1:
The patent replaces manual mechanical welding operations with an automated welding system that uses laser measurement technology to detect welding seam positions and control welding parameters. This substitution eliminates human variability and achieves consistent, high-precision welding quality through automated control of welding current, voltage, and speed based on real-time seam position feedback.
2Productivity
If manual welding operation is used, then welding can be performed, but welding efficiency reaches a bottleneck
Solution Approach 1:
The patent replaces manual welding operations with an automated welding robot system that performs detection and welding tasks automatically. The system uses laser rangefinders to detect welding seam positions and controls the welding robot to execute welding operations autonomously, significantly improving welding efficiency by eliminating manual operation bottlenecks and enabling continuous high-speed welding.
3Ease of operation
If manual welding is relied on personal experience, then welding can be performed, but standard operation is hard to realize
Solution Approach 1:
The patent replaces reliance on personal welding experience with an automated control system that uses laser measurement technology to detect welding seam positions and automatically adjusts welding parameters. The system eliminates the need for operator skill variability by using programmed control algorithms to maintain consistent welding quality, making the operation simple to initiate while ensuring precise, standardized results.
4Productivity
If automated welding system is introduced, then welding efficiency and quality are improved, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a unified automated welding system that combines laser detection, position calculation, and welding execution in one coordinated platform. The system uses a microprocessor-based control unit that handles both detection data processing and welding parameter control, reducing overall system complexity despite the advanced capabilities provided by integrating these multiple functions.
Data Source
AI summary
In the automatic welding method and device for prestressed tubular piles provided in the present application, which is applied in welding equipment, a detection is conducted around a connection position between prestressed tubular piles and a position of a target welding seam is obtained. Then the target welding seam is welded around the prestressed tubular piles according to the position of the target welding seam.