Weld Overlay Torch Positioning for Tube Distortion Compensation
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Solution Overview
Problem
Conventional weld overlay systems fail to maintain high welding quality due to distortion of elongated tubes, as they only compensate for vertical displacement, neglecting horizontal displacement, which can lead to significant quality degradation if distortion exceeds specified limits.
Innovation Solution
A weld overlay system that includes a workpiece jig, a carriage, and a welding base with rollers to maintain a constant distance between the welding torch and the tube, allowing the torch to move in two-axis directions to follow tube deformation, ensuring uniform welding and high quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the weld overlay process is continued without compensating tube distortion, then the welding process can be simplified, but the relative position of the tube with respect to the welding torch is displaced, degrading welding quality
Solution Approach 1:
The invention transitions from single-axis (vertical) copying to two-axis (horizontal and vertical) copying by adding a horizontal displacement sensor and corresponding control mechanisms. This dimensional expansion enables comprehensive compensation for tube distortion in both horizontal and vertical directions, maintaining welding quality without excessive system complexity
Solution Approach 2:
The system implements feedback control by using displacement sensors to detect tube distortion in real-time and automatically adjusting the welding torch position through servo motors. This closed-loop feedback mechanism continuously compensates for distortion, preventing welding quality degradation while maintaining reasonable system complexity
2Device complexity
If only vertical displacement is compensated by the AVC device, then the system complexity is reduced, but horizontal displacement is not compensated, leading to quality degradation when distortion exceeds specified limits
Solution Approach 1:
The invention adds horizontal displacement compensation to the existing vertical AVC system, transforming it from one-dimensional to two-dimensional copying. This is achieved by incorporating a horizontal displacement sensor and servo motor mechanism, enabling reliable welding quality consistency even when distortion exceeds specified limits
Solution Approach 2:
The welding base is designed with multi-functionality, serving both as the mounting platform for the welding torch and as the copying mechanism that follows tube distortion in two axes. This universal design consolidates multiple functions into a single integrated system, improving reliability without proportionally increasing complexity
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 system ensures uniform weld overlay by maintaining a constant distance between the welding torch and the tube, thereby securing high welding quality by compensating for both vertical and horizontal displacements, preventing quality degradation.
Implementation Method 1
a filler metal and a base metal (tube) are melted by arch heat generated between the welding torch and the base metal
Implementation Method 2
the pair of rollers are pressed against the outer peripheral surface of the workpiece to maintain a distance between the welding base and the workpiece at a constant value
Implementation Method 3
to control the temperature of the base metal during the welding, water is flowed through the tube
Data Source
AI summary
A weld overlay system includes a workpiece jig holding a workpiece in manner that the workpiece center axis direction is parallel to X-axis direction, and rotates the workpiece in circumferential direction, a carriage, welding base supported on the carriage in manner that the welding base is displaceable with respect to the carriage in Y-axis direction and Z-axis direction, at least one pair of rollers and welding torch are supported on the welding base, and like. Pair of rollers include rotary shafts extend in parallel with the X-axis and are spaced apart from each other in Y-axis direction. The rollers are pressed against portion of the workpiece above the workpiece center axis C. The welding torch is supported on the welding base in manner that distances in Y-axis direction from the rotary shafts of the pair of rollers to the tip end of the welding torch are equal to each other.