Robotic Hardfacing of Drill Bit Cutters
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Solution Overview
Problem
Current methods for applying hardfacing to steel-tooth drill bits are manual, labor-intensive, and lack consistency, leading to variable quality and high costs due to reliance on skilled welders and unsuitable robotic systems that struggle with accessing complex surfaces and programming.
Innovation Solution
A robotic system with a plasma transfer arc torch secured vertically and a programmable robotic arm that oscillates to apply hardfacing in a controlled waveform pattern, using sensors for precise positioning and material flow management, allowing for consistent and efficient application of wear-resistant coatings on steel-tooth drill bits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual welding methods are used to apply hardfacing to steel-tooth drill bits, then the process can be performed with simple equipment, but the quality consistency and productivity are poor due to reliance on skilled welders and labor-intensive operations
Solution Approach 1:
The patent replaces manual mechanical welding operations with an automated robotic system that uses a plasma transfer arc torch. The robotic arm manipulates the torch to apply hardfacing material automatically, eliminating the need for skilled welders and ensuring consistent quality. The system includes a control system that manages the welding parameters, torch oscillation, and robotic movement to achieve uniform hardfacing application.
Solution Approach 2:
The patent changes the welding process parameters by using plasma transfer arc welding instead of conventional manual welding. The system controls plasma gas flow, shielding gas flow, and arc power parameters to optimize the hardfacing application. The robotic system also controls the speed, amplitude, and frequency of torch oscillation to achieve consistent material deposition.
2Productivity
If robotic systems are used to automate hardfacing application, then productivity and consistency improve, but the device complexity and programming difficulty increase significantly
Solution Approach 1:
The patent introduces a control system as an intermediary between the operator and the complex robotic welding system. The control system manages the robotic arm, plasma power source, gas flow controllers, and torch oscillation mechanism, simplifying the operation. The system includes sensors and feedback mechanisms that automatically adjust parameters, reducing the need for complex programming and making the system more manageable.
Solution Approach 2:
The robotic system is designed to perform multiple functions: positioning the torch, controlling the plasma arc, managing gas flows, oscillating the torch for uniform deposition, and monitoring the welding process through sensors. This multi-functionality is integrated into a single automated system that handles the entire hardfacing process, improving productivity while managing complexity through integration.
3Ease of operation
If conventional welding torches are used, then the equipment is simpler, but the ability to access complex cutter surfaces and maintain precise positioning is insufficient
Solution Approach 1:
The patent employs a robotic arm with multiple degrees of freedom that can dynamically position the plasma transfer arc torch to access complex cutter surfaces. The robotic system can move in multiple axes and adjust its position and orientation in real-time, allowing the torch to reach difficult-to-access areas of the cutters while maintaining precise positioning through feedback control.
Solution Approach 2:
The system incorporates sensors that provide feedback on torch position, cutter surface geometry, and welding parameters. This feedback is used by the control system to automatically adjust the torch positioning and welding parameters, ensuring precise application of hardfacing material on complex surfaces. The feedback mechanism compensates for variations in cutter geometry and maintains consistent deposition quality.
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 system enhances the consistency and quality of hardfacing, reduces reliance on skilled labor, decreases production time, and improves the reliability and cost efficiency of steel-tooth drill bits by automating the hardfacing process while maintaining symmetry and coverage.
Implementation Method 1
a plasma arc welding torch manipulated by a positioner
Implementation Method 2
plasma arc welding torch
Data Source
AI summary
The present invention relates to a system and method for automated or “robotic” application of hardfacing to the surface of a steel-toothed cutter of a rock bit. In particular, the system incorporates a grounded adapter plate and chuck mounted to a robotic arm for grasping and manipulating a rock bit cutter beneath an electrical or photonic energy welding source, such as a plasma arc welding torch manipulated by a positioner. In this configuration, the torch is positioned substantially vertically and oscillated along a horizontal axis as the cutter is manipulated relative along a target path for the distribution of hardfacing. Moving the cutter beneath the torch allows more areas of more teeth to be overlayed, and allows superior placement for operational feedback, such as automatic positioning and parameter correction. In the preferred embodiment, sensors provide data to the control system for identification, positioning, welding program selection, and welding program correction. The control system, aided by data from the sensors, manipulates the robotically held cutter while controlling the operation and oscillation of the torch.