Tilting Internal Welding Head for Tube End Misalignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing internal clamping and welding devices for metal pipes face challenges in maintaining precise alignment and centering due to 'hi-lo' problems and lack of circularity, leading to inefficiencies and incomplete welds, which affect the sealing and resistance to fatigue of the weld bead.
Innovation Solution
An internal clamping and welding device with a tiltable welding head and pivot mechanism that allows for independent alignment with the tube end face, combined with a ball joint and indexing system to compensate for inclinations and ensure precise positioning, enabling efficient and complete welds even with imperfect tube ends.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rigid alignment means are used to maintain precise positioning of the welding head, then manufacturing precision is improved, but the device cannot accommodate tube end face inclinations and loses adaptability
Solution Approach 1:
The patent applies the dynamics principle by replacing rigid alignment means with a pivot mechanism that enables dynamic adjustment. The welding head is connected to the support via a pivot that allows the welding head to tilt and align with the tube end face inclination, transforming the system from static to dynamic and enabling adaptation to varying tube conditions while maintaining welding precision.
Solution Approach 2:
The patent implements parameter changes by introducing a pivot mechanism that changes the angular parameter of the welding head relative to the support. This allows the welding head orientation to be adjusted according to the tube end face inclination, enabling the system to adapt to different tube conditions while maintaining precise welding head positioning.
2Device complexity
If the welding head is fixed rigidly to the support, then device complexity is reduced, but alignment precision with inclined tube ends deteriorates
Solution Approach 1:
The pivot mechanism introduces controlled dynamics to the welding head support structure. Instead of a rigid fixed connection, the pivot allows dynamic adjustment of the welding head angle, enabling precise alignment with inclined tube end faces while adding only minimal structural complexity through the pivot joint and associated adjustment mechanisms.
3Stability of the object's composition
If alignment means are positioned far from the joint plane, then device stability is improved, but the ability to compensate for tube imperfections and maintain manufacturing precision deteriorates
Solution Approach 1:
The patent applies preliminary action by positioning the alignment means close to the joint plane, allowing the welding head to pre-align with the tube end face inclination before welding begins. This close positioning enables the system to compensate for tube squareness defects and imperfections in advance, maintaining manufacturing precision while the overall device structure remains stable.
4Productivity
If internal welding is performed to join tube ends edge to edge, then productivity is improved by eliminating external plates, but maintaining firm alignment and centering during welding becomes more difficult
Solution Approach 1:
The patent uses dynamics by implementing a pivot mechanism that allows the welding head to dynamically adjust its angle to maintain firm alignment and centering during internal welding operations. This dynamic adjustment capability enables precise welding without requiring external plates, thereby maintaining high productivity while managing the complexity of alignment through intelligent mechanical design.
Data Source
Figure 1
Figure 2~4
Figure 3
AI summary
An internal clamping and welding device (1) for joining tubes by their distal ends, the device comprising movement means in order to be moved inside the tubes, separate clamping means (13, 15) for cooperating with the inner surfaces of the tubes to be welded, and a welding head (17) mounted so as to be able to both rotate about a longitudinal axis of the tubes, and also pivot in order to be tiltable relative to a support of the clamping means.