Weight Balancer for Pipe Alignment and Welding
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Solution Overview
Problem
Existing pipe joining methods face challenges in aligning and welding long, heavy pipes due to manual operation difficulties, inconsistency in weld quality, and increased operational time, especially when pipes are large and have eccentric centers of gravity, leading to inefficiencies and potential damage from friction in automatic systems.
Innovation Solution
A weight balancer with a double plate operation plate, equipped with load cells, a controller, and leveling cylinders, which supports 6 degrees of freedom motion, is integrated with an automatic pipe aligning device to precisely adjust the height, location, and vibration of pipes, reducing load and enabling precise alignment and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual pipe aligning operation is performed by adjusting the position of simple jigs, then the pipe alignment can be achieved, but the operation time becomes very long and the precision is difficult to maintain, especially when the pipe is long and heavy
Solution Approach 1:
The patent replaces manual mechanical adjustment operations with an automatic pipe aligning device that uses sensors, controllers, and automated positioning mechanisms. The device automatically detects pipe positions, calculates alignment requirements, and executes positioning operations without manual intervention, thereby dramatically reducing operation time while maintaining or improving alignment precision.
Solution Approach 2:
The automatic pipe aligning device performs self-measurement and self-positioning operations. The device equips sensors to detect pipe positions and dimensions, automatically calculates alignment parameters, and executes positioning without external control, enabling the system to service itself and eliminate manual operational delays.
2Manufacturing precision
If automatic pipe aligning device is used to support 6 degrees of freedom motion, then the alignment precision is improved, but the device complexity increases
Solution Approach 1:
The patent divides the complex 6-degree-of-freedom positioning system into separate functional modules: three linear actuators for X, Y, Z axis positioning and three rotational actuators for roll, pitch, and yaw adjustments. Each module independently controls one degree of freedom, simplifying the overall system architecture while achieving precise six-axis positioning capability.
Solution Approach 2:
The automatic pipe aligning device integrates multiple functions into a single system: it performs measurement, calculation, positioning, and alignment operations simultaneously. The device can handle various pipe configurations and alignment requirements through programmable control, reducing the need for multiple specialized devices and justifying the complexity through multifunctional capability.
3Adaptability or versatility
If the center of gravity is eccentric from the center of volume according to the shape of the pipe, then the pipe shape can be complex, but the manual aligning operation becomes very difficult and the operation time increases
Solution Approach 1:
The patent incorporates sensors that detect the actual position, orientation, and weight distribution of pipes with eccentric centers of gravity. The controller receives this feedback information and automatically adjusts positioning commands to compensate for gravitational imbalances and irregular shapes, enabling accurate alignment of complex pipe configurations without increasing manual operation difficulty.
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 solution enables rapid and precise alignment and welding of pipes, improving weld quality, reducing operational time, and minimizing load-related issues, while maintaining stability and accuracy even with heavy and large pipes.
Implementation Method 1
a load cell (145, 146) for detecting the load of the pipe (13)
Implementation Method 2
a plurality of leveling cylinders (150) and balancing devices (160) which are connected to the pressure supply lines to control a location or pose of the operation plate (180)
Data Source
AI summary
The present invention relates to a weight balancer (100) and a pipe joining method that is capable of reducing a load of pipes when arranging and welding the pipes in ships, plants, piping work sites and the like. A weight balancer (100) according to the present invention includes an operation plate (180) for putting an alignment object; a plurality of load cells (145,146) installed in the lower portion of the operation plate (180); a controller (120) which receives a detection signal generated from the load cell (145,146) and analyzes the information of the alignment object to generate a control signal; an operation force driver (130) which receives the control signal from the controller (120) to control an operational pressure of each of a plurality of pressure supply lines; and a plurality of leveling cylinders (150) and balancing devices (160) which are connected to the pressure supply lines to control a location or pose of the operation plate (180) so as to correspond to the size of the operational pressure controlled by the operation force driver (130).