Screen Welding Apparatus for Metal Filter Net Leakage Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing screens using metal nets in the petroleum industry face challenges such as low welding strength, leakage holes, and high costs due to limitations in conventional welding technologies, which affect the sand control capacity and reliability of the screens.
Innovation Solution
The method employs resistance spot welding or seam welding technology to directly combine metal nets with a base pipe, eliminating leakage holes and improving the sand control capacity and lifespan of the screens, while also reducing manufacturing costs through two-side one-point welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional arc welding or plasma arc welding is used to weld metal net, then welding strength is improved, but leakage holes (shrinkage hole phenomena) appear on welding parts
Solution Approach 1:
The patent replaces conventional arc welding (thermal field-based) with resistance welding (electrical field + mechanical pressure-based). The welding head applies direct electrical current and mechanical pressure to the metal net and base pipe simultaneously, creating a solid-state bond without melting. This substitution eliminates the shrinkage hole phenomenon caused by thermal contraction while maintaining strong welding strength through direct metallurgical bonding.
Solution Approach 2:
The patent changes the welding parameters from high-temperature arc welding to controlled electrical resistance welding with specific current intensity, pressure, and duration parameters. By adjusting these parameters (current 100-500A, pressure 0.5-5MPa, time 0.1-2 seconds), the process achieves reliable welding without creating leakage holes, resolving the contradiction between strength and reliability.
2Reliability
If multi-layer sintered metal net is used as filter material, then solderability and welding quality are improved, but factory cost increases and productivity decreases
Solution Approach 1:
The patent replaces expensive multi-layer sintered metal net with single-layer metal net that has adequate service life for the application. The resistance welding process creates such reliable bonds that the simpler, cheaper single-layer net performs as well as or better than complex multi-layer sintered nets, improving productivity while maintaining welding quality.
Solution Approach 2:
The patent extracts the essential function of filtration from complex multi-layer sintered structures and implements it with simpler single-layer metal net. The resistance welding technology compensates for the simplicity by providing superior bonding reliability, thereby achieving the same welding quality with reduced material complexity and lower cost.
3Ease of manufacture
If single-layer metal net is used as filter material, then factory cost is reduced, but welding strength is insufficient and mechanical fixing is required
Solution Approach 1:
The patent replaces mechanical fixing methods (clamps, bands, compression) with resistance welding that creates direct metallurgical bonds between the single-layer metal net and base pipe. This electrical-mechanical welding process generates sufficient welding strength through controlled electrical current and pressure, eliminating the need for additional mechanical fixing components while keeping manufacturing cost low.
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 approach enhances the welding quality of metal nets, increases the sand control capacity, and extends the lifespan of the screens, providing a cost-effective solution for high-quality screen production.
Implementation Method 1
uses resistance spot welding or seam welding technology to directly combine metal nets and connect them to base pipe etc
Implementation Method 2
uses resistance spot welding or seam welding technology to directly combine metal nets and connect them to base pipe etc
Data Source
AI summary
The present invention relates to a method for manufacturing a screen and welding apparatus thereof, putting a metal filter net around the outside of a support sheath and fixing the metal filter net to the outside of the support sheath by way of welding, such that the metal filter net completely covers all filter holes of the support sheath to form a filter sheath with; fixing the filter sheath to the outside of the base pipe and the filter sheath completely covering all penetrated holes on the base pipe; putting a jacket around the outside of the filter sheath and fixing it to the outside of the base pipe such that the jacket completely covers the outside surface of the filter area of the filter sheath. The present invention uses direct spot welding and seam welding technology to fix the metal net to the outside of the support sheath directly, eliminates leakage hole phenomena appearing on jointing parts of the metal net and forms the screen with multi-layer metal nets with improved sand control capability and life time. The present invention also discloses the apparatus for above-said screen to realize penetrated welding of the filter sheath so as to improve the welding quality of the metal net and lower the factory cost of the screen.