Wire Wrapped Screen Welding Pressure Control
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Solution Overview
Problem
Existing wire wrapping machines struggle to maintain consistent weld pressure during the manufacturing of wire wrapped screens, leading to inconsistent welds and potential issues with sand control in hydrocarbon production.
Innovation Solution
A welding pressure control apparatus and method that includes a movable welding support assembly with mechanical actuator cylinders and a force measurement device, utilizing a control and feedback system to adjust welding pressure and maintain consistent force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional wire wrapping machines are used, then the manufacturing process is simple, but weld pressure consistency deteriorates
Solution Approach 1:
The patent implements a feedback control system where a force measurement device (load cell) continuously monitors the welding force applied to the wire-rib assembly. The control system processes this feedback signal and adjusts the positioning of the welding device to maintain consistent weld pressure throughout the wrapping process, directly resolving the weld pressure consistency issue.
Solution Approach 2:
The patent replaces traditional mechanical positioning systems with an automated control system that uses electrical signals from the load cell to actuate positioning mechanisms. This substitution of mechanical feedback with electronic control enables precise weld pressure maintenance while managing system complexity through modular design.
2Strength
If weld pressure is increased to improve weld quality, then weld strength improves, but energy consumption increases
Solution Approach 1:
The patent employs dynamic adjustment of weld pressure through the feedback control system. Rather than applying constant high pressure, the system continuously monitors weld force and dynamically adjusts positioning to maintain optimal pressure levels. This dynamic control achieves consistent weld strength while minimizing energy consumption by avoiding excessive force application.
Solution Approach 2:
The control system monitors and adjusts welding parameters (positioning force, timing) in real-time based on feedback from the load cell. By changing these parameters dynamically rather than maintaining fixed high values, the system achieves reliable weld strength with optimized energy consumption.
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
Ensures consistent and uniform welds throughout the wire wrapping process, enhancing the quality and reliability of wire wrapped screens used in sand control applications.
Implementation Method 1
A force measurement device indicates support assembly force transmitted to the welding device
Implementation Method 2
Mechanical actuator cylinders mounted on the support assembly and the mounting structure provide load balance
Data Source
AI summary
An apparatus for manufacturing wire wrapped screens utilizing a wire and support ribs is provided. The apparatus employs welding pressure control, utilizing a welding device mounted on a support assembly, wherein the support assembly is moveable in relation to a mounting structure and the wire and support rib weld pieces. Welding pressure is determined by a force measurement device, and a control and feedback system adjusts pressure. Mechanical actuator cylinders mounted on the support assembly and the mounting structure provide load balance. A method for making wire wrapped screens is also provided.