Portable Robotic Welder With Joint Tracking for Canister Lid Sealing
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Solution Overview
Problem
Manual welding of nuclear waste canister lids in high radiation environments exposes workers to significant radiation risks and does not ensure consistent weld quality, as current methods require prolonged human interaction with the welding area.
Innovation Solution
An automated robotic welding system using a portable robotic welder (PRW) controlled by a microcontroller, which allows for remote operation and real-time data monitoring to achieve higher weld deposition rates and minimize human exposure to radiation, forming a hermetic seal weld in the lid-to-shell closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual welding is used for lid-to-shell closure, then weld quality can be monitored by liquid penetrant process, but worker radiation exposure increases significantly
Solution Approach 1:
The patent replaces manual mechanical welding operations with an automated robotic welding system. The robotic welder performs the welding task remotely, eliminating the need for workers to physically position themselves in high-radiation zones near the canister lid, thereby reducing radiation exposure while maintaining weld quality through automated precision and consistent parameter control
Solution Approach 2:
The robotic welder acts as an intermediary between the operator and the welding task. The operator controls the welding process remotely from a safe location, and the robotic system executes the welding operations, serving as a mediator that transfers the harmful radiation exposure from human workers to the robotic system
2Productivity
If manual welding operations are performed in high radiation field, then weld deposition can be completed, but operation time increases due to safety precautions
Solution Approach 1:
The automated robotic welding system operates continuously without the interruptions required for manual safety briefings, radiation monitoring checks, and worker rotation. The robot can maintain optimal welding parameters and speed throughout the entire lid-to-shell closure process, significantly reducing total operation time while increasing weld deposition rate
3Object-affected harmful factors
If automated robotic welder is used, then radiation exposure is minimized, but device complexity increases
Solution Approach 1:
The robotic welder is designed as a multi-functional integrated system that combines welding capabilities, positioning systems, and remote control functions in a single platform. This universal device can perform multiple tasks including approach positioning, weld execution, and parameter adjustment, reducing the need for multiple separate complex systems while achieving radiation minimization
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 automated system effectively reduces radiation exposure for human operators and ensures high-quality welds by implementing factory automation in a high-radiation field setting, aligning with the ALARA principle of minimizing radiation doses.
Implementation Method 1
Hermetic seal welding of the closure lid to the top of the canister shell is then carried out
Data Source
AI summary
An automated welding system for sealing high level radioactive waste containers in the field at the nuclear plant site. The system includes a programmable portable robotic welder comprising a multi-jointed articulating robotic arm. A welding head operable to form a weld is mounted to the arm. Operation of the robotic welder and ancillary components is controlled by a programmable controller which implements a welding plan. In one embodiment, a circumferentially-extending lid-to-shell hermetic seal weld may be formed by the robotic welder. The weld is completed in multiple welding passes through the weld joint between the lid and shell guided by an automated joint tracking sensor linked to the controller. The highly portable robotic welder is detachably mountable on the lid to perform the welding. An automated pivotable cable-conduit management apparatus keeps electrically conductive wiring and flow tubing out of the path of the rotating robotic arm during welding.