Rotating Welding Assembly for Space-Saving H-Beam Welding
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Solution Overview
Problem
Current submerged arc welding plants for steel H beams require significant space and are hazardous due to complex control and high noise levels, with gantry cranes causing productivity issues and frequent maintenance needs.
Innovation Solution
An automated welding assembly that rotates 180° on a support surface, using chain-operated tilting means and hydraulic telescopic arms to precisely control the movement and alignment of steel beams, eliminating the need for gantry cranes and reducing noise and accident risks, while utilizing rollers for beam movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a gantry crane is used to transfer and tilt the T profile, then the welding plant can process H beams, but the production space required increases significantly
Solution Approach 1:
The patent combines the functions of the gantry crane, tilting mechanism, and welding assembly into a single integrated welding assembly. The welding assembly can receive workpieces from both infeed and outfeed rollers and perform welding operations without requiring separate gantry crane equipment, thereby reducing the production space while maintaining the capability to process H beams.
Solution Approach 2:
The welding assembly is designed with multi-functionality to perform multiple operations including receiving workpieces from different directions, welding, and coordinating with tilting means. This universal design eliminates the need for dedicated gantry crane equipment, reducing space requirements while preserving H beam processing capability.
2Productivity
If a gantry crane is used to transfer the T profile, then the welding plant can complete the welding process, but the complexity of control increases requiring multiple operators
Solution Approach 1:
The patent merges the control functions of the gantry crane, tilting mechanism, and welding assembly into a single automated control system. The welding assembly coordinates with the tilting means and roller systems through integrated control, reducing the number of operators from three to one or two while maintaining complete welding process capability.
Solution Approach 2:
The patent replaces the mechanical gantry crane system with an automated control system that coordinates the welding assembly and tilting means. This substitution reduces mechanical complexity and control requirements, allowing fewer operators to manage the complete welding process.
3Ease of operation
If tilting means are used to tilt the T profile, then the web can be positioned for welding, but noise levels exceed 85 Decibels
Solution Approach 1:
The patent employs hydraulic or pneumatic tilting means instead of mechanical lever systems. These fluid-powered mechanisms operate more quietly while effectively positioning the web for welding, reducing noise levels below 85 Decibels while maintaining ease of operation.
4Ease of operation
If steel tilting levers are used, then the T profile can be tilted, but the levers wear frequently requiring maintenance
Solution Approach 1:
The patent replaces steel tilting levers with hydraulic or pneumatic actuators that have no direct mechanical contact during operation. This eliminates wear on tilting components, significantly reducing maintenance frequency while preserving the tilting capability necessary for web positioning.
Solution Approach 2:
The patent substitutes mechanical tilting levers with a fluid-powered actuation system. This replacement eliminates the wear inherent in mechanical contact systems, reducing maintenance requirements while maintaining the essential tilting function for positioning the web during welding operations.
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
This solution enhances productivity, optimizes space usage, reduces accident risks, and simplifies control, allowing for efficient welding of steel H profiles with reduced downtime and maintenance needs.
Implementation Method 1
The welding assembly (104) is designed to rotate about itself on a support surface by 180° about a relative vertical axis
Implementation Method 2
chain operated tilting means, for tilting the first flange and the web by 180° on the second rollers
Implementation Method 3
suspension means equipped with hydraulic telescopic arms, to keep suspended in position the first flange and/or the web when in movement
Implementation Method 4
utilizing rollers for beam movement
Implementation Method 5
submerged arc welding sector
Data Source
Figure 1~4
Figure 5~7
Figure 8~13
AI summary
Described is a welding assembly (104) designed to be positioned in line between first rollers (101 ) and second rollers (103) of a plant (100) for the welding of steel beams with an H profile starting from a first flange (6), a web (7) and a second flange (8) to be welded together, characterised in that it is designed to rotate about itself by 180 ° about a relative vertical axis, in such a way as to receive the web (7), the first flange (6) and/or the second flange (8), both when coming from the first rollers (101 ) and when coming from the second rollers (103). The invention also relates to a relative plant (100) for the welding and a method for its operation.