Welded Ring End Offset for Higher-Quality Flush Seams
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing welded rings face challenges such as high minimum production quantities, low flexibility with different diameters, and high storage costs, along with issues in achieving flush welds and weld quality, particularly in the overlap area.
Innovation Solution
Introducing an offset in the band plane in the circumferential direction of the ring, where welding is performed from both ring side edges outside in, reducing melt flow and improving weld quality by controlling the overlap area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is performed from both ring side edges to join strip ends, then a continuous weld seam is achieved, but a double molten pool forms at the overlap point reducing weld quality
Solution Approach 1:
The patent introduces an asymmetric offset at the strip end overlap region, where one strip end extends beyond the other by a predetermined distance. This asymmetric configuration prevents the formation of a double molten pool at the overlap point by ensuring that the weld seams do not converge at the same location, thereby eliminating the defect while maintaining continuous weld coverage.
2Ease of manufacture
If strip ends are welded directly without offset, then the welding process is simpler, but a double molten pool forms at the overlap point creating weld defects
Solution Approach 1:
The offset configuration is prepared in advance during the strip positioning stage, before the welding process begins. By pre-establishing the asymmetric overlap geometry, the welding process itself requires no additional complexity - the weld seams naturally follow the offset configuration and avoid forming a double molten pool, thus improving weld quality without increasing manufacturing complexity.
3Manufacturing precision
If weld seams overlap in the center region, then continuous weld coverage is achieved, but melt flow effects reduce weld quality in the overlap area
Solution Approach 1:
The asymmetric offset configuration shifts the overlap region away from the center of the ring, creating an asymmetric weld seam distribution. This prevents the convergence of two molten pools at the overlap point, as the offset ensures that one weld seam terminates before the other begins, thereby eliminating melt flow interference while maintaining continuous weld coverage through the offset region.
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
This method enhances weld quality and tensile strength by minimizing the effects of double melt pools at the overlap, resulting in a higher quality and more consistent weld.
Implementation Method 1
the welding is carried out from both ring side edges or the strip edges from the outside to the inside up to the offset
Data Source
Figure 1~3
Figure 4~7
AI summary
For producing a welded ring, a strip of a length corresponding to the circumference of the ring is bent into a ring and is welded at its ends (10, 11). The ends of the strip (10, 11) that are to be welded to one another have in the circumferential direction of the ring an offset (12) that lies in the plane of the strip. The welding is performed from both side edges of the ring (13, 14), from the outside to the inside, as far as the offset (12). Welding having an overall improved welding quality and a higher tensile strength is thus obtained.