Polymer-Enhanced Pipe Welding with 3D Shape Detection
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Solution Overview
Problem
The production of polymer-enhanced pipe elements from pipe sections subject to tolerances faces challenges such as corrosion focus formation and impaired surface coating due to shape deviations and welding inaccuracies, particularly in fire extinguishing systems and industrial environments.
Innovation Solution
A method involving the detection of three-dimensional shapes of pipe sections, determination of a common spatial penetration curve, and alignment of edge surfaces for precise welding, allowing for the production of polymer-enhanced pipe elements with a continuous weld seam and improved surface coating quality, even with pipes having up to 1% diameter and 10% wall thickness tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pipe sections subject to tolerances are used for economical production, then productivity and cost-effectiveness are improved, but manufacturing precision and surface coating quality deteriorate due to shape deviations and welding inaccuracies
Solution Approach 1:
The patent applies preliminary action by detecting the three-dimensional shapes of pipe sections and determining cut contours and spatial penetration curves before the welding process. This pre-planning allows the welding system to compensate for tolerances in pipe diameter, wall thickness, and roundness, ensuring accurate welding paths and high-quality surface coating even when using economical pipe sections with tolerances.
Solution Approach 2:
The patent utilizes parameter changes by dynamically adjusting welding parameters based on the detected three-dimensional shapes of pipe sections. The system modifies cut contours, spatial penetration curves, and welding paths according to actual pipe geometry, enabling precise welding and high-quality polymer enhancement despite variations in pipe dimensions within tolerance ranges.
2Device complexity
If pipe sections with shape deviations are welded without compensation, then device complexity is reduced, but reliability deteriorates due to corrosion focus formation and impaired surface coating
Solution Approach 1:
The patent implements feedback by using detection devices to measure the actual three-dimensional shapes of pipe sections and using this information to determine accurate cut contours and spatial penetration curves. This closed-loop approach ensures that welding parameters are optimized based on real pipe geometry, preventing corrosion foci and ensuring reliable surface coating quality without requiring overly complex manual compensation procedures.
Solution Approach 2:
The patent replaces manual mechanical welding preparation with automated detection and calculation systems. Instead of relying on complex manual measurements and adjustments, the system uses three-dimensional shape detection, automated cut contour determination, and spatial penetration curve calculation to achieve reliable welding results, reducing device complexity while maintaining or improving reliability.
3Strength
If complete root fusion is achieved through traditional welding, then strength is improved, but manufacturing precision deteriorates due to welding deformations affecting subsequent pickling and coating processes
Solution Approach 1:
The patent applies preliminary action by determining the spatial penetration curve and cut contours before welding, based on detected three-dimensional pipe shapes. This pre-planning ensures that the welding process achieves complete root fusion while maintaining precise weld seam geometry, as the welding path and parameters are optimized in advance to compensate for expected deformations.
Solution Approach 2:
The patent utilizes parameter changes by dynamically adjusting welding parameters along the spatial penetration curve to achieve complete root fusion while controlling weld seam geometry. The system modifies welding current, speed, and position based on the detected pipe shapes and calculated penetration curves, ensuring both strength and geometric precision without requiring subsequent pickling corrections.
Data Source
AI summary
A method and apparatus for the automated or partially automated production of a polymer-enhanced pipe element, which include: providing a first pipe section and a second pipe section, each having a connecting region; detecting in the connecting regions a three-dimensional shape of the first pipe section and the second pipe section; determining a spatial penetration curve as a function of a superposition of the three-dimensional shapes; determining a cut contour, as a function of the penetration curve, in each of the connecting regions of the first pipe section and the second pipe section; generating edge surfaces in the connecting regions of the first and second pipe sections along the respective cut contours; aligning the generated edge surfaces of the pipe sections; and welding the first and second pipe sections along the mutually aligned edge surfaces along the determined spatial penetration curve.