Trimmed Edge Pipe Element With Dual Cams for Welding
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Solution Overview
Problem
Existing methods for forming a pipe element with a trimmed edge for welding onto a carrier face challenges in achieving reliable full penetration welds, especially with automated processes, due to precision requirements and quality issues related to air gaps and cam positioning.
Innovation Solution
The pipe element features a trimmed edge with at least two cams that allow it to be precisely positioned on a carrier, creating a well-defined air gap between the cams, which facilitates superior weld results by ensuring a consistent angle and orientation, thereby improving the reliability of the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the trimmed edge is beveled to create a triangular cross-section welding region, then the full penetration weld quality is improved, but the positioning precision requirements increase and automated welding reliability deteriorates
Solution Approach 1:
The trimmed edge is segmented into multiple functional zones: a first cam region for initial positioning and fillet welding, a second cam region for full penetration welding with air gap, and a third cam region for final positioning. This segmentation allows each zone to perform its specific function optimally without compromising overall reliability
Solution Approach 2:
Different regions of the trimmed edge are given different geometric properties: the first cam has a geometry suitable for fillet welding with the carrier, while the second cam creates an air gap for full penetration welding. Each local region is optimized for its specific welding mode, improving both quality and automated process reliability
2Device complexity
If a single cam is provided on the trimmed edge for positioning, then the device complexity is reduced, but the positioning precision and weld quality deteriorate
Solution Approach 1:
Instead of a single cam, the trimmed edge is divided into multiple cam regions (first, second, and third cams) that work sequentially. Each cam provides a specific positioning function, and their combined effect achieves high positioning precision without requiring an overly complex single-component mechanism
Solution Approach 2:
The first cam performs preliminary positioning and fillet welding before the pipe element is moved to the second cam region for full penetration welding. This preliminary action prepares the joint in a controlled manner, ensuring proper alignment is established before the critical full penetration welding operation
3Manufacturing precision
If the pipe element is positioned with exacting precision on the carrier, then the weld quality is improved, but the ease of operation and automated process reliability worsen
Solution Approach 1:
The trimmed edge geometry itself provides the positioning function through its cam regions. The first cam automatically positions the pipe element for fillet welding, and the second cam automatically positions it for full penetration welding with the appropriate air gap. This self-positioning mechanism eliminates the need for external positioning devices or manual adjustment, improving both ease of operation and automated process reliability
Data Source
AI summary
The present disclosure relates to a pipe element with a trimmed edge for welding onto a carrier, wherein the trimmed edge is cut from a base tube so that the pipe element can be arranged on the surface of the carrier and welded to it along the trimmed edge, wherein the trimmed edge has a first cam with which the pipe element can be placed on the surface of the carrier. It is further provided that the trimmed edge has at least one second cam with which it can be placed on the surface of the pipe element, so that an air gap remains between the surface of the carrier and the trimmed edge in a region lying between the first cam and the second cam.