Steel Pipe Arc Welding with Fewer Bead Joints
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for welding polygonal/square steel pipes and circular steel pipes face inefficiencies due to the use of multiple steel frame erection adjusting tools, which block grooves and hinder continuous welding, leading to high difficulty in the first and second layers and increased likelihood of weld defects.
Innovation Solution
A gas shield arc welding method that involves attaching a steel frame erection adjusting tool to fix a groove, performing initial layers via semiautomatic or manual welding, removing the tool, and using a welding robot to complete subsequent layers with minimized bead joints, optimizing weld start and end points, and adjusting welding conditions to prevent defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple steel frame erection adjusting tools are used to fix the groove, then the positioning accuracy is improved, but the continuity of welding is hindered and the number of joints increases
Solution Approach 1:
The welding process is divided into two stages: initial layers welded with multiple adjusting tools for positioning accuracy, and remaining layers welded after removing tools for continuity. This segmentation resolves the contradiction by applying different approaches to different phases of the welding process.
Solution Approach 2:
The initial layers are welded first while the adjusting tools are still in place to establish accurate positioning. After this preliminary action is complete, the tools are removed to enable continuous welding of remaining layers without obstruction.
2Manufacturing precision
If multiple steel frame erection adjusting tools are used to fix the groove, then the positioning accuracy is improved, but the number of bead joints increases leading to more weld defects
Solution Approach 1:
The welding process is divided into two stages: initial layers welded with multiple adjusting tools for positioning accuracy, and remaining layers welded after removing tools for continuity. This segmentation resolves the contradiction by applying different approaches to different phases of the welding process.
Solution Approach 2:
The steel frame erection adjusting tools are removed after the initial layers are welded, extracting the positioning function when no longer needed. This eliminates the obstruction to continuous welding and reduces the number of bead joints in the critical remaining layers.
3Manufacturing precision
If semiautomatic or manual welding is used for initial layers, then the positioning accuracy is improved, but the work efficiency is reduced
Solution Approach 1:
The welding process is divided into two stages: initial layers welded with multiple adjusting tools for positioning accuracy, and remaining layers welded after removing tools for continuity. This segmentation resolves the contradiction by applying different approaches to different phases of the welding process.
Solution Approach 2:
The initial layers are welded first while the adjusting tools are still in place to establish accurate positioning. After this preliminary action is complete, the tools are removed to enable continuous welding of remaining layers without obstruction.
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 method reduces the number of joints prone to defects, enabling highly efficient automatic welding with a welding robot, improving work efficiency and reducing weld defects.
Implementation Method 1
remaining layers are welded by a welding robot so that bead joints are formed at two sites or less
Data Source
AI summary
A gas shield arc welding method that reduces the number of joints, which are the sites where defects occur more readily, and that enables automatic welding with a welding robot. A gas shield arc welding method in which a steel pipe Wo is welded by multi-pass welding with a steel frame erection adjusting tool attached to an erection piece on the steel pipe Wo to immobilize an open end section of the steel pipe. An initial single or several layers are welded to the open end section, after welding, the steel frame erection adjusting tool is removed; and remaining layers are welded with a welding robot such that two bead joints are formed at no more than two sites.