Rotating Welding Torch With External Laser Alignment
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Solution Overview
Problem
Conventional pipeline welding systems face challenges in accurately aligning pipe segments, inspecting weld quality, and efficiently cooling pipes, particularly in remote locations, leading to inefficiencies and potential errors in the welding process.
Innovation Solution
A field system that includes internal and external welding mechanisms with laser-based alignment and inspection tools, and a cooling system that can be deployed internally within the pipes to facilitate precise alignment, real-time weld inspection, and rapid temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional internal alignment mechanisms are used to align pipe segments, then alignment is achieved, but internal clutter increases and space for rotating torch is reduced
Solution Approach 1:
The alignment mechanism is extracted from the internal welding system and placed externally on the pipe surface. The external alignment mechanism uses rollers and alignment tools that contact the external surface, eliminating the need for internal expanders and reducing internal clutter while maintaining alignment accuracy.
Solution Approach 2:
An external alignment mechanism serves as an intermediary between the pipe segments and the welding torch. This external mechanism provides alignment references and positioning without occupying internal space, allowing the welding torch to rotate freely inside the pipe.
2Manufacturing precision
If laser-based tracking is implemented to control torch position, then welding precision improves, but system complexity increases
Solution Approach 1:
The mechanical alignment and positioning system is replaced with an optical laser-based tracking system. Lasers project reference lines and patterns onto the pipe interface, and cameras or sensors detect these patterns to automatically control torch position, replacing complex mechanical alignment mechanisms with simpler optical fields.
Solution Approach 2:
The laser system creates optical copies or projections of alignment references onto the pipe surface. Instead of physical alignment tools, laser beams project geometric patterns that serve as virtual alignment guides, simplifying the physical system while maintaining precision.
3Temperature
If internal cooling system is deployed within pipes, then cooling efficiency increases, but device complexity and installation difficulty increase
Solution Approach 1:
The cooling system is nested within the existing internal welding system structure. Cooling elements such as heat exchangers or coolant delivery mechanisms are integrated into the welding apparatus that is already inserted into the pipe, allowing the cooling system to be deployed without separate installation procedures.
Solution Approach 2:
The cooling function is merged with the welding operation. The same internal apparatus that performs welding also provides cooling, combining multiple functions into a single integrated system that reduces overall complexity and simplifies deployment.
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 enables accurate alignment and inspection of pipe segments, improves weld quality, and accelerates the cooling process, reducing errors and increasing efficiency in pipeline welding operations.
Implementation Method 1
a laser scanner for scanning the face joint profile and providing position feedback for torch control
Implementation Method 2
The cooler system applies cooling to an interior surface of the pipes to accelerate cooling
Data Source
AI summary
A field system for welding two pipes includes a first pipe engagement structure, a second pipe engagement structure, one or more weld torches, a motor and one or more processors. The one or more weld torches are configured to be positioned within the pipes to create an internal weld at an interface region between the pipes. The motor is operatively associated with the one or more weld torches to rotate the one or more weld torch along the interface region between the pipes. The one or more processors control the motor and the one or more weld torches. The one or more processors operate the motor and the one or more weld torches to generate a complete circumferential weld along the interface region by rotating the one or more weld torches along the interface region in a single rotational direction until the complete circumferential weld is completed.