Tube End Compatibility Index for Faster Welding Alignment
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Solution Overview
Problem
Current methods for assembling pipelines require time-consuming and costly interventions to ensure compatibility between tubular elements, leading to inefficiencies and high production costs due to frequent misalignments and incompatibilities, especially during welding operations.
Innovation Solution
A method is developed to generate an index of compatibility between the ends of tubular elements by marking angular references, measuring orbital characteristics, determining angular compatibility indexes, and calculating an overall compatibility score, which categorizes pairs as compatible, compatible with controlled angular presentation, or incompatible, facilitating efficient pairing and reducing the need for on-site corrections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional measurement and alignment methods are used for tubular elements, then welding compatibility can be achieved, but the process requires time-consuming interventions and repeated measurements, reducing productivity
Solution Approach 1:
The patent applies preliminary action by marking angular references on tubular elements during manufacturing before they reach the welding site. This pre-marking enables direct use of the markings for alignment during welding operations, eliminating the need for time-consuming on-site measurements and interventions. The angular markings are prepared in advance so that when tubes need to be welded, the alignment can be quickly achieved by referencing these pre-established marks, thus maintaining reliability while significantly improving productivity.
2Reliability
If traditional on-site measurement and correction methods are used, then compatibility issues can be identified and corrected, but the process requires complicated operations and qualified personnel, increasing device complexity and costs
Solution Approach 1:
The patent extracts the measurement and alignment function from the welding process itself and transfers it to the manufacturing stage. By marking angular references on the tubes during production, the complex measurement and correction operations are eliminated from the on-site welding process. The markings carry the alignment information forward, so that during welding, operators simply need to reference the pre-marked angles rather than performing complex measurements and corrections, thus reducing device complexity and the need for specialized equipment.
Solution Approach 2:
The patent uses copying by creating angular reference markings that replicate the essential alignment information needed for welding. These markings are copied from the manufacturing jigs or reference systems used during tube production and transferred onto the tube surfaces. During welding, these copied markings serve as sufficient guides for alignment, eliminating the need for complex measurement devices and qualified personnel to perform sophisticated measurements and corrections.
3Reliability
If tubular elements are processed late-stage for compatibility corrections, then incompatibility issues can be addressed, but the operations become extremely expensive and time-consuming, increasing loss of time and productivity
Solution Approach 1:
The patent prevents late-stage compatibility corrections by performing the alignment preparation in advance during manufacturing. Angular references are marked on the tubular elements before they leave the production line, ensuring that compatibility is established upfront rather than being corrected later. This preliminary action eliminates the need for expensive and time-consuming late-stage interventions, as the tubes arrive at the welding site already prepared for efficient alignment and welding operations.
Data Source
AI summary
Method for generating a compatibility index between two ends of two tubes, in particular before welding operations, the method comprising the steps of: (a) marking an angular reference (M0) on each of the two ends, (b) orbital measurement of an inside radius of each of the ends; (c) determining an index of angular compatibility (INDthētak) between the two ends for an angular deviation (⊖, theta) between the angular references of the ends, said angular compatibility index deriving from a maximum difference between the inside radii of each opposite end, (d) iterating the step of determining the angular compatibility index for several values for angular deviation between the angular references of the ends; (e) generating an overall score for compatibility (Hk) between said two ends, the overall compatibility score being a function of the angular compatibility indices determined for several angular deviation values.