Pneumatic Rotating Welding Torch for Low-Chamfer Riser Joints
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Solution Overview
Problem
Existing electric arc welding techniques face challenges when applied to risers with straight or composite chamfers, requiring extensive machining and high filler metal consumption, which increases manufacturing time and costs.
Innovation Solution
A rotating arc welding torch utilizing a pneumatic turbine and cooling system, capable of reducing chamfer angles, minimizing filler metal consumption, and reducing machining time, while being compatible with any welding source regardless of manufacturer or age.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional electric arc welding processes are used on risers with straight or composite chamfers, then welding can be performed, but extensive machining and high filler metal consumption are required, increasing manufacturing time and costs
Solution Approach 1:
The patent applies a rotating consumable electrode mechanism that dynamically adjusts the welding arc trajectory. The rotation of the consumable allows the arc to sweep across the joint, enabling welding on risers with straight or composite chamfers without requiring extensive machining preparation. This dynamic rotation reduces both machining time and filler metal consumption by optimizing material deposition patterns.
Solution Approach 2:
The invention changes the welding parameters by introducing rotational motion to the consumable electrode. This parameter change allows the welding process to accommodate various chamfer configurations (straight or composite) without requiring precise machining preparation, thereby reducing manufacturing time and filler metal consumption while maintaining weld quality.
2Productivity
If a rotating consumable electrode mechanism is implemented, then chamfer angle reduction and filler metal consumption optimization are achieved, but device complexity increases
Solution Approach 1:
The patent utilizes pneumatic principles to drive the rotation of the consumable electrode. A pneumatic turbine or motor integrated into the torch assembly provides rotational motion through compressed gas, eliminating the need for complex mechanical drive systems. This pneumatic approach achieves the required rotation while keeping the device relatively simple and maintenance-free.
Solution Approach 2:
The invention replaces complex mechanical rotation mechanisms with a pneumatic drive system. By using compressed gas to rotate the consumable electrode, the design avoids intricate mechanical components such as gears, belts, or motors, thereby reducing device complexity while maintaining welding speed and productivity.
3Loss of time
If extended welding cycles are used to reduce machining operations, then manufacturing time is reduced, but heat accumulation and torch overheating occur
Solution Approach 1:
The patent implements continuous water cooling of the torch body and consumable electrode holder throughout the welding process. This continuous cooling action allows extended welding cycles to be performed without interruption for torch cooling, enabling the elimination or reduction of machining operations while preventing heat accumulation and torch overheating.
Solution Approach 2:
The invention utilizes the phase transition of water from liquid to vapor through evaporation and boiling in the cooling channels to absorb excessive heat. The water circulation system maintains the torch at safe operating temperatures during extended welding cycles, allowing continuous operation without thermal damage while reducing overall manufacturing time by eliminating machining steps.
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 solution significantly reduces the total manufacturing time of riser joints, lowers filler metal consumption, and decreases costs by allowing for extended use with 100% cycle efficiency on NEMA class I welding machines, and compatibility with various welding sources.
Implementation Method 1
the gas used in the welding process, or even the compressed air, enters through a conductor in the axial direction to the consumable, moving, in this way, a turbine, which in turn moves the components called tip and tip holder
Implementation Method 2
since it is water cooled, it can be used for welding in straight or nearly straight chamfers (composite)
Data Source
AI summary
The invention uses the principle of the pneumatic turbine and a cooling system for the entire welding torch, wherein the gas used in the welding process, or even compressed air, enters through a conductor in the axial direction to the consumable, thus moving, a turbine, which in turn moves a tip and a tip holder. The welding torch can be used for extended periods of time at 100% cycle on welding machines of NEMA class I, since it is water cooled. In addition, the torch can be used in any welding source from any manufacturer, whether the machine is new or very old, as the euro standard (socket) is the same. This implies that there is no need to purchase a new welding machine, but only a torch. In construction and assembly environments, such as riser welding, refineries, joint welding, coating, and processes that aim to build a part using only one welding consumable, the use of said torch would bring a significant balance in terms of reduction of time and cost. This torch can also be used in any existing welding device, within the abovementioned processes.