Ring Gear Welding System for Pipe Joints with Enlarged Profiles
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Solution Overview
Problem
The challenge in pipeline welding at sea is ensuring the quality and speed of weld joints under high tension, where manual control of the welding arc is necessary to achieve strong and consistent welds, but this is inefficient and prone to errors in repetitive processes.
Innovation Solution
An automated welding system utilizing a ring gear assembly and weld head assemblies with position sensors and motorized positioning, allowing for precise orbital paths and automatic adjustment of the welding torch to maintain consistent weld quality and increase efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual control of the welding arc is used, then weld quality can be maintained through operator skill, but welding speed is slow and productivity is low
Solution Approach 1:
The patent replaces manual mechanical control of the welding arc with an automated system using position sensors, motors, and controllers to precisely position the welding torch along the groove, thereby maintaining weld quality while enabling continuous high-speed operation
Solution Approach 2:
The welding system incorporates self-positioning capabilities through sensors that automatically detect the groove geometry and adjust the torch path accordingly, eliminating the need for manual operator intervention while maintaining consistent weld quality at high speeds
2Productivity
If automated welding systems are implemented, then welding speed and productivity increase, but the complexity of the device increases
Solution Approach 1:
The welding system is designed as a multi-functional integrated unit that combines groove detection, path planning, torch positioning, and welding execution in a single automated platform, thereby achieving high productivity without proportionally increasing overall system complexity
Solution Approach 2:
The patent introduces a controller as an intermediary that coordinates between sensors, motors, and welding parameters, simplifying the overall system architecture by centralizing control logic and reducing the need for complex direct connections between components
3Manufacturing precision
If the welding torch is positioned precisely along the groove, then weld quality is maintained, but the time required for positioning and welding increases
Solution Approach 1:
The system enables continuous welding motion by pre-calculating the optimal torch path and maintaining constant forward movement along the groove, eliminating stop-and-go positioning operations while preserving precise arc contact geometry throughout the welding process
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 enhances weld joint quality and significantly increases welding speed, reducing operational costs and minimizing the risk of human error in repetitive pipeline welding processes.
Implementation Method 1
A ring gear assembly and at least one weld-head assembly mounted on the ring gear assembly. The weld-head assembly including a mounting plate comprising: i) a welding torch, ii) a torch positioner, and iii) a position sensor
Implementation Method 2
A line of pipe sections extend through the ring gear and are positioned independent of the traveling carriage. The system controller is programmed to control the traveling carriage and the weld-head to perform the steps of: welding of the pipe joint with a welding torch
Data Source
AI summary
A method of welding a pipe section in a ring-based welding system, wherein the welding system comprises: (i) an adjustable ring gear mount; (ii) a ring gear assembly positioned on the adjustable ring gear mount, the ring gear assembly having an inner diameter and a center point; and (iii) at least one weld head assembly mounted on the ring gear assembly. The method includes steps of: (a) positioning the pipe section within the ring gear assembly, the pipe section having an object attached the pipe section which enlarges a cross-sectional profile of the pipe section; (b) moving the pipe section through the ring gear assembly in a direction substantially parallel to the pipe section's longitudinal axis; (c) operating the adjustable ring gear mount to move the center point of the ring gear assembly relative to the pipe center point in a plane substantially orthogonal to the pipe section's longitudinal axis; and (d) moving the attached object through the ring gear assembly while the ring gear assembly remains an enclosed circular structure.