Welding Temperature Control for Rotating Cylindrical Components

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Solution Overview

Problem

Current methods for verifying and controlling temperature during welding operations on cylindrical components are inadequate, leading to temperature excursions and potential damage due to infrequent monitoring and manual adjustments, which can result in components failing to meet specification requirements.

Innovation Solution

A system that includes sensors to monitor the rotation and temperature of components during welding, using a programmable logic controller to receive signals from rotation and temperature sensors, and adjust the welding flame automatically to maintain temperature within set limits, while also providing alarms for operator intervention when necessary.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If temperature verification and welding flame adjustment occur infrequently (e.g., hourly or bi-hourly), then operator workload is reduced, but temperature excursions occur that cause components to fail specification requirements

Engineering Contradiction:

Improveoperator workloadVSAvoidtemperature control precision

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The system enables self-service by implementing automatic temperature monitoring and control where the welding assembly autonomously adjusts flame intensity based on real-time temperature feedback from sensors, eliminating the need for manual operator intervention and frequent temperature verification

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system implements continuous feedback control by monitoring component temperature in real-time during welding operations and automatically adjusting flame intensity based on the feedback signal, preventing temperature excursions and maintaining precise temperature control throughout the welding process

Inventive Principle:

Principle #23Feedback

2Device complexity

If manual temperature verification and flame adjustment methods are used, then device complexity is reduced, but localized overheating occurs when component rotation ceases and goes unnoticed

Engineering Contradiction:

Improvemonitoring system complexityVSAvoidwelding process reliability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The system implements self-service monitoring where sensors continuously track component rotation status and temperature conditions, automatically detecting when rotation ceases and triggering appropriate responses without requiring operator attention or complex manual monitoring systems

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system ensures continuous monitoring of temperature and rotation status throughout the welding process, maintaining uninterrupted surveillance that immediately detects anomalies such as stopped rotation, preventing localized overheating and ensuring welding reliability

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If temperature monitoring is performed continuously, then temperature control precision is improved, but device complexity increases due to additional sensors and control systems

Engineering Contradiction:

Improvetemperature control precisionVSAvoidmonitoring and control system complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system achieves precise temperature control through self-service automation where the control system autonomously processes sensor data and adjusts welding parameters without requiring complex manual control mechanisms or operator intervention

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system replaces manual mechanical temperature verification methods with automated sensor-based monitoring and electronic control systems, achieving continuous precise temperature control while the overall system remains integrated and manageable through automated processes

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 consistent temperature control throughout the welding process, preventing excursions and ensuring components meet specifications, thereby reducing the risk of damage and improving the quality of welds.

Implementation Method 1

providing a first sensor that is operatively engaged with the component so that the first sensor monitors rotation or non-rotation of the components

Methodology Applied

Scientific EffectRotation detection:

Implementation Method 2

A second sensor is operatively engaged with the component and is configured to detect a temperature of the component

Methodology Applied

Scientific EffectTemperature detection:

Implementation Method 3

producing a flame with the flame torch

Methodology Applied

Scientific EffectCombustion: Combustion

Data Source

PatentUS11213912B2Methods and systems for monitoring a temperature of a component during a welding operation

Publication Date: 2022.01.04 BWXT NUCLEAR OPERATIONS GROUP INC

AI summary

A method of monitoring a heating operation on an component by a flame torch, including the steps of producing a flame with the flame torch, rotating the component with respect to the flame so that a circular weld is created on the component, and providing a first sensor that is operatively engaged with the component so that the first sensor monitors rotation or non-rotation of the components.