Pivoting Index Bar Assembly for Tank Dome Weld Overlay
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Solution Overview
Problem
Conventional weld overlay machines are not adapted to transition smoothly between the curved domes and cylindrical sides of tanks, requiring manual removal and installation of separate components, leading to delays and increased costs.
Innovation Solution
A weld overlay machine assembly with a pivoting index bar that can rotate up to 180 degrees, allowing it to adapt to curved surfaces without needing additional components, and an adjustable torch position to compensate for distance changes, enabling seamless transition between tank sides and domes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional overlay machines use fixed index bar configuration, then they can operate on cylindrical surfaces, but they cannot transition to domed surfaces without manual component changes
Solution Approach 1:
The index bar is made dynamically adjustable through a telescoping mechanism with multiple extendable sections that can be extended or retracted to change the overall length and angle of the index bar, allowing the machine to adapt to different surface geometries (cylindrical vs. domed) without manual component changes
Solution Approach 2:
The system changes the geometric parameters of the index bar (length and angle) by extending or retracting the telescoping sections, enabling the same machine configuration to operate on both cylindrical and domed surfaces by adjusting these parameters rather than changing components
2Adaptability or versatility
If manual removal and installation of separate components is used for dome transitions, then the machine can adapt to curved surfaces, but operational delays and costs increase
Solution Approach 1:
The telescoping index bar provides continuous dynamic adjustment capability, allowing smooth transition between different surface geometries during operation without stopping to change components, thereby maintaining productivity while achieving adaptability
Solution Approach 2:
The telescoping index bar mechanism serves multiple functions: it enables operation on cylindrical surfaces in retracted configuration and domed surfaces in extended configuration, making the machine universally applicable to both surface types without requiring separate components
3Ease of operation
If the index bar is fixed in position, then the machine structure is simpler, but it cannot compensate for distance changes when transitioning between tank sides and domes
Solution Approach 1:
The telescoping index bar automatically adjusts its length through the relative movement of extendable sections, providing dynamic compensation for distance changes between the torch and tank surface during transition from cylindrical to domed sections without requiring complex external control mechanisms
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
Enables efficient and cost-effective application of a corrosion-resistant weld overlay on tanks with curved surfaces by eliminating the need for manual component changes, reducing operational delays and costs.
Implementation Method 1
a torch (117) configured to apply heat to a workpiece
Implementation Method 2
apply heat to a workpiece
Implementation Method 3
pivoting of the index bar perpendicular to and relative to the track
Data Source
AI summary
A weld overlay machine assembly includes a carriage to support a hinged index bar and a wire feed assembly. The index bar has an auto height control unit and an index assembly to locate the position of a weld torch relative to the index bar. The assembly is configured to adjust the index bar to interior contours of the vessel while applying a layer of overlay material to a surface therein. The assembly runs along a track in the interior of the vessel. The assembly is configured to transition from sides of the vessel to that of the top or bottom domes wherein the curve of the domes are perpendicular to that of the radial sides. This transition is done without the need to add or remove components to the assembly. This is accomplished by providing the pivoting of the index bar relative to the track.