Internal Pipeline Welding with Laser-Guided Torch Alignment
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Solution Overview
Problem
Conventional pipeline welding systems face challenges in accurately aligning and positioning welding torches within pipes, often resulting in internal clutter and difficulty in assessing the accuracy of the weld, especially when using external alignment mechanisms, and lack visual inspection capabilities for weld quality.
Innovation Solution
A system that employs external alignment mechanisms with rollers and motors to position pipe segments, integrates a laser for tracking the pipe interface profile to control the welding torch's position and orientation, and includes a camera for visual inspection of the weld.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If internal alignment mechanisms are used to align pipe segments from inside, then alignment can be achieved without external equipment, but the expander structure creates significant internal clutter and does not allow sufficient space for a rotating or articulating torch
Solution Approach 1:
The patent inverts the conventional approach by performing alignment externally rather than internally. External alignment mechanisms position the pipe segments relative to each other before the internal welder is inserted, allowing the internal welder to operate in a clutter-free environment with full rotational freedom for the torch.
2Manufacturing precision
If conventional internal welders are used with expandable alignment mechanisms, then alignment can be achieved, but the structure must accommodate a rotating torch which limits the expander design and increases complexity
Solution Approach 1:
The patent divides the welding system into two independent parts: an external alignment system that positions pipe segments, and an internal welding system that performs the actual welding. This segmentation allows each system to be optimized independently, with the internal welder having a simple, compact structure without complex expandable alignment mechanisms.
3Manufacturing precision
If external alignment mechanisms with rollers and motors are used to position pipe segments, then alignment can be achieved, but there is no capability to visually inspect the weld applied by the torch
Solution Approach 1:
The patent incorporates a camera system that provides real-time visual feedback of the welding process. The camera is positioned to observe the weld as it is being applied, allowing operators to monitor weld quality and make adjustments if necessary, thereby solving the inspection capability problem.
4Measurement precision
If manual high-low gauges are used for alignment assessment, then alignment can be evaluated at discrete locations, but the profile or structure of the interface as observed from the inside of the pipe is not considered and accuracy assessment is limited
Solution Approach 1:
The patent uses a laser scanner to create a digital copy or map of the pipe interface profile from the inside of the pipe. This laser-based profiling captures the complete geometric information of the joint, which can then be used to verify alignment accuracy and guide the welding process, preserving information that manual gauges cannot detect.
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 ensures accurate alignment and quality control of welds by using laser-tracked interface profiles to guide the welding torch and provides visual feedback on weld quality, enhancing the precision and effectiveness of the welding process.
Implementation Method 1
track a profile of the interface with a laser
Implementation Method 2
weld the joint
Data Source
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Figure 3
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AI summary
The present invention is directed to a system for welding together segments of a pipeline. The system includes an external alignment mechanism for externally supporting and manipulating the orientation of pipe segments in order to align relative segments. The system also includes an internal welding mechanism for applying a weld to an interior face joint of the two abutted pipe segments. The internal welding mechanism including a torch for applying a weld, a laser for tracking the weld profile and guiding an articulating head of the torch, and a camera for visually inspecting the weld after the weld is applied.