True-Circle Weld Groove Formation for Automated Pipe Spool Welding

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Solution Overview

Problem

The challenge in the pipe spool manufacturing industry is the difficulty in automating the process due to varying shapes and sizes, leading to manual and semi-automatic welding, which is time-consuming and prone to defects, and requires significant manpower and paper-based management systems.

Innovation Solution

A weld groove forming method using a sensor robot to determine if a pipe's end can be processed into a true circle and an automatic beveling machine to form a true circular weld groove, enabling automated welding by scanning and cutting the pipe's inner and outer walls to specific thickness profiles for efficient and defect-free connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual or semi-automatic welding is used, then flexibility in handling various pipe shapes and sizes is maintained, but welding time and manpower requirements increase significantly

Engineering Contradiction:

Improveflexibility in handling various pipe shapes and sizesVSAvoidwelding time and manpower requirements

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent changes the geometric parameters of the weld groove to a true circular cross-section with specifically controlled thickness distribution. This parameter optimization enables automated welding processes to achieve consistent quality across various pipe shapes and sizes, resolving the contradiction between adaptability and productivity by making the welding process parameter-independent of manual adjustment.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent segments the welding process into distinct phases: groove formation by automatic beveling machine, sensor verification of true circular geometry, and automated welding execution. This segmentation allows each phase to be optimized independently, with the true circular groove geometry enabling full automation while maintaining versatility through programmable control.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If manual welding operations are performed, then complex pipe spool configurations can be handled, but welding defects occur more frequently

Engineering Contradiction:

Improvecapability to handle complex pipe spool configurationsVSAvoidwelding defects

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent incorporates sensor robots that scan and measure the weld groove geometry to verify true circular cross-section and proper thickness distribution before automated welding begins. This feedback mechanism ensures consistent groove quality and enables real-time verification, eliminating the variability and defects associated with manual welding while maintaining the ability to handle complex configurations through programmable control.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual welding operations with an automated welding system that uses a true circular groove geometry and sensor-verified measurements. This substitution eliminates human error and variability in welding execution, significantly reducing welding defects while maintaining the capability to handle complex pipe spool configurations through automated positioning and control systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If automated welding is implemented, then welding efficiency increases, but the weld groove must be formed as a true circle which requires additional processing steps

Engineering Contradiction:

Improvewelding efficiencyVSAvoidadditional processing steps for true circular groove formation

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent performs preliminary action by forming the true circular weld groove geometry using an automatic beveling machine before the welding process begins. The sensor robot verifies the true circular geometry and thickness distribution in advance. This preliminary preparation enables subsequent automated welding to proceed efficiently without interruptions or adjustments, as the groove geometry is pre-optimized for automated welding processes.

Inventive Principle:

Principle #10Preliminary action

4Ease of operation

If traditional paper-based management systems are used, then flexibility in manual operations is maintained, but time and resources are consumed in documentation and tracking

Engineering Contradiction:

Improveflexibility in manual operationsVSAvoidtime consumed in documentation and tracking

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The patent replaces paper-based management systems with automated digital control and monitoring systems that integrate with the automatic beveling machine and welding equipment. Sensors and controllers automatically track and record all processing parameters, groove geometry measurements, and welding conditions, eliminating manual documentation while maintaining operational flexibility through programmable control interfaces.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11897058B2Weld groove forming method and hollow article

Publication Date: 2024.02.13 SAMSUNG E&A CO LTD

AI summary

The present disclosure relates to a weld groove forming method and a hollow article. The weld groove forming method may include: (S110) determining whether a side end of a pipe may be processed into a form of a true circle by using a sensor robot; and (S220) forming a weld groove in a form of a true circle at the side end of the pipe by using an automatic beveling machine when the sensor robot determines that the side end of the pipe may be processed into a form of a true circle in the step (S110).