Pipe Spool Weld Groove Alignment for Robotic Circular Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manual and semi-automated welding processes in pipe spool manufacturing are time-consuming and prone to defects, especially when dealing with complex shapes and varying sizes of pipe spools, which complicates automation and increases manpower requirements.
Innovation Solution
An automatic welding method utilizing a material transport robot, gap sensor robot, and GT/GM welding robots to align and weld pipes and connection members with true circular weld grooves, enabling efficient root and filling/cap welding of 2D and 3D spools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual and semi-automated welding processes are used, then flexibility in handling complex shapes and varying sizes of pipe spools is maintained, but welding time and manpower requirements increase significantly
Solution Approach 1:
The invention changes the geometric parameters of the weld groove to a true circular form, which enables automated welding processes to handle complex shapes efficiently. This parameter change allows the welding system to maintain flexibility while significantly improving productivity through automation.
Solution Approach 2:
The invention replaces manual and semi-automated welding operations with fully automated welding robots. This substitution eliminates the need for manual intervention in welding tasks, reducing welding time and manpower requirements while maintaining the ability to handle complex pipe spool configurations.
2Adaptability or versatility
If manual welding operations are performed, then complex shapes and varying sizes can be accommodated, but welding defects occur more frequently
Solution Approach 1:
The invention replaces manual welding operations with automated welding robots, which provide consistent and precise welding execution. This substitution eliminates human error and variability, significantly reducing welding defects while maintaining the ability to accommodate varying sizes and complex shapes through programmable control.
Solution Approach 2:
The invention incorporates feedback mechanisms in the automated welding system, including sensors and control systems that monitor welding parameters in real-time. This feedback ensures consistent welding quality by automatically adjusting parameters to maintain optimal welding conditions, thereby preventing defects.
3Measurement precision
If multiple responsible personnel are assigned to each manufacturing process, then drawing management and inspection tasks can be performed, but the overall manufacturing efficiency decreases
Solution Approach 1:
The invention integrates multiple functions including drawing management, member management, inspection tasks, and welding operations into a single automated control system. This multi-functional system eliminates the need for multiple responsible personnel while maintaining inspection accuracy through automated sensing and control mechanisms.
Solution Approach 2:
The automated welding system performs inspection and quality verification functions automatically without requiring separate inspection personnel. The system self-monitors welding parameters, detects defects, and ensures quality standards are met, thereby improving manufacturing efficiency while maintaining measurement precision.
Data Source
AI summary
The automatic welding method includes: carrying a pipe on which a true circle weld groove and settling the pipe at a fit-up position in the welding station and carrying a hollow connection member on which a true circle weld groove is formed to a position near the fit-up position in the welding station by using the material transport robot; measuring the alignment state of the hollow connection member with respect to the fit-up position by using a gap sensor robot, and according to the results, moving the position of the hollow connection member to align the weld groove of the pipe with the weld groove of the hollow connection member; performing a root welding on the aligned weld grooves by using a GT welding robot; and performing a filling and cap welding on the aligned weld grooves by using a GM welding robot to manufacture a 2D spool.