Tube End Compatibility Indexing for Faster Weld Alignment
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Solution Overview
Problem
Current methods for ensuring watertight and mechanically strong welds between tubular elements, such as line pipes, are time-consuming and costly due to the need for frequent adjustments and corrections of misaligned ends, leading to production slowdowns and increased handling complexity.
Innovation Solution
A method for generating a compatibility index between the ends of tubular elements by measuring orbital characteristics, determining angular compatibility indices, and assigning an overall compatibility score to optimize the assembly process, reducing the need for on-site adjustments and improving weld quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional measurement and adjustment methods are used to ensure compatibility between tubular element ends, then weld quality can be maintained, but the process becomes time-consuming and reduces productivity
Solution Approach 1:
The patent applies preliminary action by measuring and determining the compatibility index of tubular element ends before assembly. The system measures geometric characteristics (out-of-roundness, diameter, chamfer angles) and calculates compatibility indices in advance, allowing incompatible elements to be identified and replaced before they reach the welding station, thus maintaining weld quality without slowing down the assembly process
Solution Approach 2:
The patent implements feedback by using measurement data from the geometric characteristics of tubular ends to calculate compatibility indices, which then feed back into the assembly process. This feedback mechanism allows the system to automatically identify incompatible pairs and adjust the assembly sequence or replace elements, ensuring weld quality while optimizing productivity through data-driven decision-making
2Reliability
If frequent adjustments and corrections of misaligned ends are performed, then compatibility between tubular elements can be ensured, but handling complexity and costs increase
Solution Approach 1:
The patent applies preliminary action by performing measurements and compatibility assessments before assembly. By determining compatibility indices in advance and identifying incompatible elements early in the process, the system eliminates the need for frequent on-site adjustments and corrections, thereby reducing handling complexity while ensuring compatibility
Solution Approach 2:
The patent introduces an intermediary compatibility index calculation system that acts as a mediator between measurement data and assembly decisions. This intermediary system processes geometric measurements and generates compatibility assessments, simplifying the decision-making process and reducing the complexity of manual handling and adjustment operations
3Reliability
If incompatible tubular elements are identified and corrected on-site, then weld quality can be maintained, but production time is lost and costs increase
Solution Approach 1:
The patent applies preliminary action by measuring and determining compatibility indices before assembly. Incompatible elements are identified in advance, allowing for proactive replacement or repositioning before they reach the welding station, thus maintaining weld quality without causing production delays
Solution Approach 2:
The patent applies skipping by enabling the assembly line to quickly bypass incompatible tubular element pairs through automated identification and alternative selection. The system can rapidly skip over incompatible elements and proceed to compatible ones, minimizing the time lost and maintaining high production rates while ensuring weld quality
Data Source
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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 (INDthêtak) between the two ends for an angular deviation (Ө, 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.