Valve Body End Welding With Predictive Distortion Compensation
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Solution Overview
Problem
The valve manufacturing industry faces challenges due to high product variation and low quantity, leading to inventory issues and long production lead times caused by customer-specific inlet and outlet end connection configurations, which are difficult to manage with conventional welding processes that suffer from weld distortion.
Innovation Solution
A computer-implemented method using predictive algorithms for an automated welding process that allows late-customization of valve bodies by iteratively adjusting the welding process to add custom end connections to generic valve bodies, reducing the need for customer-specific inventory and shortening production lead times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional welding processes are used to add custom end connections to valve bodies, then customer-specific configurations can be produced, but weld distortion occurs and production lead times increase
Solution Approach 1:
The patent applies preliminary action by pre-calculating and pre-planning the welding sequence and parameters using predictive algorithms before the actual welding process. The system determines the optimal welding path and parameters in advance to compensate for expected distortion, allowing custom end connections to be added to valve bodies without suffering from uncontrolled weld distortion during execution
Solution Approach 2:
The patent implements feedback by using predictive algorithms that incorporate material properties, welding parameters, and geometric constraints to forecast and adjust for weld distortion in real-time or near-real-time. This feedback mechanism allows the system to maintain manufacturing precision while producing customer-specific configurations by continuously comparing predicted versus actual distortion and making corrective adjustments
2Productivity
If inventory levels of customer-specific valve configurations are reduced, then production flexibility improves, but the ability to meet customer demand timely may worsen without predictive capabilities
Solution Approach 1:
The patent applies preliminary action by performing predictive calculations of welding distortion and required adjustments before the actual welding process begins. This pre-computation enables the system to quickly produce custom valve configurations on-demand without lengthy trial-and-error welding processes, thereby maintaining short production lead times while improving production flexibility through reduced inventory needs
Solution Approach 2:
The patent replaces traditional mechanical trial-and-error welding approaches with a computational predictive algorithm system. Instead of physically attempting welds and measuring distortion iteratively, the system uses software-based predictive modeling to determine optimal welding parameters in advance, significantly reducing production lead times while enabling on-demand customization
3Device complexity
If sales forecasting is relied upon to produce customer-specific valves, then production planning is simplified, but inventory waste increases when forecasts are inaccurate
Solution Approach 1:
The patent replaces the mechanical approach of producing physical inventory based on sales forecasts with a computational on-demand manufacturing system. The predictive algorithms enable valves to be customized and produced only when orders are received, eliminating the need for large inventory holdings and associated waste from inaccurate forecasting, while keeping production planning relatively simple
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
Enables the reduction of inventory levels and reliance on sales forecasting by allowing generic valve bodies to be customized on demand, maintaining accurate specifications while minimizing weld distortion and production delays.
Implementation Method 1
adjoining the selected first end connection to the valve body at the initial first end connection by: (i) performing an operation based on an initial bias, (ii) comparing the actual results of the operation to predicted results of the operation
Data Source
AI summary
A method and apparatus are provided for late-customization of a valve body having an initial valve body configuration having a first end connection and a second end connection. The method includes receiving a selection of (i) a generic valve body, (ii) a first end connection, and (iii) a second end connection. The method further includes adjoining the first and second end connections to the valve body using an iterative welding process. The apparatus is configured to receive a generic valve body having an initial end configuration and to receive a different end configuration. Ends are connected to the valve body subject to an initial bias and a comparison between actual results and predicted results, and first end connection is iteratively welded.