Wire Wrap Welding System Linear Induction Drive Precision

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Solution Overview

Problem

Existing wire wrap screen manufacturing systems face challenges in maintaining consistent slot spacing and tolerance due to long screen lengths and component wear, affecting the precision of wire slot openings in well screens used for sand control in oil, gas, and water wells.

Innovation Solution

A wire wrap welding system incorporating a linear induction drive system and a linear encoder system for controlled movement of the tailstock, combined with a servomotor for spindle rotation and a welding pressure control system to ensure precise slot openings and consistent welding quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If traditional wire wrapping machines with lead screws and ball screws are used to manufacture long wire screens, then the screens can be produced, but slot spacing tolerance deteriorates due to component wear over time

Engineering Contradiction:

Improvescreen lengthVSAvoidslot spacing tolerance

Core Design Contradiction:

Length of moving objectVSManufacturing precision

Solution Approach 1:

The patent replaces traditional mechanical drive systems (lead screws, ball screws, helical gear racks) with a linear induction motor system. This eliminates mechanical contact and wear between moving components, thereby maintaining slot spacing tolerance consistency throughout the entire screen length without degradation from component wear.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent incorporates feedback control systems with encoders that continuously monitor the position of the tailstock and adjust the linear induction motor operation accordingly. This closed-loop control ensures that slot spacing tolerance is maintained within specified limits throughout the manufacturing of long screens.

Inventive Principle:

Principle #23Feedback

2Device complexity

If traditional mechanical drive systems are used, then the manufacturing process is simpler, but slot spacing consistency deteriorates over long screen lengths

Engineering Contradiction:

Improvedrive system complexityVSAvoidslot spacing consistency

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent replaces complex mechanical transmission systems with a linear induction motor that directly drives the tailstock along the screen length. This substitution maintains manufacturing precision over long distances while the overall system complexity is managed through integrated control systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If wire screens are manufactured in long sections greater than forty feet, then productivity increases, but slot spacing tolerance deteriorates due to cumulative errors

Engineering Contradiction:

Improvescreen length productionVSAvoidslot spacing tolerance

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The linear induction motor eliminates cumulative positioning errors that occur with traditional mechanical systems over long distances. By using electromagnetic fields for direct drive without intermediate mechanical components, the system maintains tolerance consistency throughout screens greater than forty feet in length.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The feedback control system with encoders continuously monitors and corrects position deviations throughout the manufacturing process, enabling production of long screens while maintaining slot spacing tolerance within specified limits.

Inventive Principle:

Principle #23Feedback

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 achieves precise control over wire slot openings and welding pressure, maintaining tolerance and consistency throughout the length of the screen, enhancing the effectiveness of sand control in well screens.

Implementation Method 1

a linear induction drive system for controlled movement of the tailstock

Methodology Applied

Scientific EffectLinear induction: Electromagnetic Induction

Implementation Method 2

a linear encoder system comprising a series of position encoders disposed on the bed

Methodology Applied

Scientific EffectLinear encoder: Electromagnetic Induction

Implementation Method 3

weld the wire to, multiple support ribs

Methodology Applied

Scientific EffectElectrical resistance welding: Joule Heating

Data Source

PatentUS9919354B2Wire screen manufacturing system and method

Publication Date: 2018.03.20 DELTA SCREEN & FILTRATION LLC

AI summary

An exemplary embodiment of wire wrap welding system generally includes a headstock; a bed; a bed mounted tailstock linearly moveable in relation to the headstock; a linear induction drive system adapted to move the tailstock; a linear encoder system having a series of position encoders disposed on the bed; a servomotor adapted to rotate a headstock mounted spindle; a welding system positioned on the headstock, a servomotor positioned on the tailstock and adapted to rotate a tailstock mounted spindle; and a control system. An exemplary embodiment of a method for controlling slot openings between wire segments in a wire wrap welding process generally includes controlling movement of a bed mounted tailstock in relation to the rate of rotation of a headstock mounted spindle, utilizing a linear induction drive system, a linear encoder system, and a control system.