Tube End Positioning via Sensor-Based Radial Offset Control
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Solution Overview
Problem
Current methods for positioning tubes for welding fail to achieve precise coincidence of end surfaces, particularly for tubes with chamfered ends, leading to defects in welds due to manufacturing tolerances and geometric imperfections, resulting in incomplete contact and poor weld quality.
Innovation Solution
A method and device using a flange system with hydraulic cylinders and sensors to assess and control radial offsets between tube ends, allowing for precise alignment and deformation of tubes to achieve 20-100% surface coincidence, utilizing a central computing unit to process sensor data and control cylinder movements for optimal positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional positioning methods are used to align tubes for welding, then the positioning process is simple, but the coincidence of end surfaces is poor leading to weld defects
Solution Approach 1:
The patent replaces conventional mechanical positioning methods with a sensor-based measurement system. Sensors measure the actual positions and orientations of tube ends, and a computing unit processes this data to determine precise positioning, substituting mechanical alignment with electronic measurement and calculation.
Solution Approach 2:
The patent creates a digital copy or model of the actual tube geometry by measuring the tube ends with sensors. This digital representation is then used by the computing unit to calculate the optimal positioning, allowing precise alignment without physically manipulating the tubes during the calculation phase.
2Manufacturing precision
If tube ends are machined to improve alignment, then the end surfaces are more regular, but the internal profile imperfections are reproduced in the chamfers
Solution Approach 1:
The patent uses sensors to measure the actual tube end geometry and feeds this information back to the computing unit. The system then calculates compensation values that account for the measured imperfections, allowing the positioning system to compensate for variations rather than requiring perfect machining.
Solution Approach 2:
The patent changes the approach from modifying tube geometry through machining to modifying the positioning parameters based on measured actual geometry. The system adjusts positioning calculations to account for the actual tube dimensions and profiles, rather than attempting to make all tubes identical through machining.
3Manufacturing precision
If flanges with cylinders are used to deform and position tubes, then the tubes can be aligned, but the radial offset between tube ends remains difficult to control precisely
Solution Approach 1:
The patent replaces manual or mechanical estimation of radial offset with sensor-based measurement. The sensors directly measure the radial offset between tube ends, and the computing unit processes this data to determine the precise positioning required, eliminating the need for manual measurement and calculation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method ensures better grip and quality of the first weld pass by achieving a greater surface coincidence of tube ends, reducing radial offsets and ensuring reliable welding even under challenging conditions.
Implementation Method 1
A positioning device is provided comprising a flange comprising two homologous flanges, mounted one on the other, one of the flanges supporting a first set of hydraulic cylinders, while the other flange supports a second set of hydraulic cylinders
Implementation Method 2
The radial offset between the tube ends is assessed, and the positioning device controls the movements of the cylinders so as to bring the tube ends to a position in which the radial offset has a predetermined value
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3C
AI summary
The invention relates to a method for mutually positioning tubes. In said method, and end face, which includes a generally annular and generally circular end surface (101, 201) near an inner surface (102, 202) of the tube (100) and a beveled edge surface (103A, 203A) connecting the end surface (101, 201) to an outer surface (105, 205) of the tube, is provided on a first tube (100) and on a second tube (200), respectively. A plurality of clamping cylinders are engaged with the first tube (100) and with the second tube (200), respectively. Each cylinder is radially arranged onto the respective tube thereof, and the cylinders are evenly distributed around the respective tubes (100, 200) thereof. The first and second tube are pre-positioned relative to each other such that the respective end faces thereof are opposite each other. At least one radial offset (H, H') is assessed between the respective end surfaces or end edges of the first and second tube. The clamping cylinders of the first and/or second tube are moved relative to each other in accordance with the assessed radial offset(s) (H, H') on the basis of an optimization of the areas in which the respective end surfaces or end edges of said tubes coincide.