CN115229427A - System and method for welding pipe sections of pipeline - Google Patents

Abstract

A system for welding two pipes includes a first pipe clamp, a second pipe clamp, a welding torch, an inspection detector, a motor, one or more processors, and a grinder. The welding torch is configured to form a welded joint between the tubes at an interface region between the tubes. The inspection detector is configured to emit a beam of inspection radiation. The motor is operably associated with the inspection detector to direct the inspection radiation beam along the welded joint between the tubes. The one or more processors are operably associated with the inspection detector to determine a profile of the welded joint between the tubes. The grinder is configured to grind at least a portion of the welded joint between the tubes based on the profile of the welded joint between the tubes.

Description

System and method for welding pipe sections of pipeline

This application is a divisional application of a patent application (international filing date July 18, 2017, application number 201780003163.7, invention title "system and method for welding pipe sections of pipes").

technical field

The present patent application relates to systems and methods for welding pipe or pipe sections.

Background technique

Piping systems may include long lengths of pipe sections or lengths (eg, miles of pipe) comprising steel, stainless steel, or other types of metals used to transport, for example, water between two locations , oil and natural gas, etc. (eg, from a source that may be land or water based to a suitable storage location). The construction of piping systems typically involves joining together pipe sections of suitable diameter and length dimensions via welded joints, eg, capable of providing a liquid-tight seal to the joined pipe sections.

During the formation of a welded joint between two pipes or pipe sections (eg, two pipe sections having the same or similar cross-sectional dimensions), the end of one pipe section or pipe section is in close proximity to the end of the other pipe section or pipe section or touch. The pipe sections are held relative to each other and welded joints are formed to connect the two ends of the pipe sections using a suitable welding process. After the soldering is complete and cleaned, the soldering can be inspected.

The present patent application provides improvements over prior art systems and methods.

SUMMARY OF THE INVENTION

One aspect of the present patent application provides a system for welding two pipes. The system includes a first pipe clamp, a second pipe clamp, a welding torch, an inspection detector, a motor, one or more processors, and a grinder. The first tube clip is configured to engage the outer surface of the first tube to enable the first tube clip to be secured relative to the first tube. The second tube clip is configured to engage the outer surface of the second tube to enable the second tube clip to be secured relative to the second tube. The welding torch is configured to form a welded joint between the tubes at the interface region between the tubes. The inspection detector is configured to emit a beam of inspection radiation. A motor is operably associated with the inspection detector to direct a beam of inspection radiation along the welded joint between the tubes. The one or more processors are operably associated with an inspection detector to determine a profile of the welded joint between the tubes. The grinder is configured to grind at least a portion of the welded joint between the tubes based on the profile of the welded joint between the tubes.

Another aspect of the present patent application provides a system for welding two pipes. The system includes a pipe clamp assembly, a welding torch, and an enclosure. The pipe clamp assembly includes a first pipe clamp and a second pipe clamp. The first tube clip is configured to engage the outer surface of the first tube to enable the first tube clip to be secured relative to the first tube. The second tube clip is configured to engage the outer surface of the second tube to enable the second tube clip to be secured relative to the second tube. A welding torch is operably connected to the pipe clamp assembly and is configured to form a welded joint between the pipes at an interface region between the pipes. An envelope is operably connected to the tube clamp assembly and is configured to envelope an interface region between the torch and the tube.

Another aspect of the present patent application provides a system for welding two pipes. The system includes: a first pipe clamp configured to engage an outer surface of the first pipe to enable the first pipe clamp to be secured relative to the first pipe; a second pipe clamp configured to engage an outer surface of the second pipe a surface to enable the second pipe clamp to be secured relative to the second pipe; a welding torch configured to form a welded joint between the pipes at an interface region between the pipes; and an inspection detector configured to emit inspection radiation bundle.

These and other aspects of the present patent application, as well as the method of operation and function of the related elements of structure and the combination of parts and economics of manufacture, will become more apparent upon consideration of the following description and appended claims with reference to the accompanying drawings, all of which form this specification part of , wherein like reference numerals refer to corresponding parts throughout the various figures. In one embodiment of the present patent application, structural components shown herein are drawn to scale. It should be expressly understood, however, that the drawings are for purposes of illustration and description only and are not intended to serve as a definition of limitations to this patent application. It should also be understood that features of one embodiment disclosed herein may be utilized in other embodiments disclosed herein. As used in the specification and the claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. In addition, as used in the specification and the claims, the term "or" means "and/or" unless the context clearly dictates otherwise. It is also to be understood that some components and features discussed herein may be discussed in conjunction with only one (singular) of such components and that additional similar components that may be disclosed herein may not be discussed in detail in order to reduce redundancy. By way of example only, where a single torch is described, the same configuration may be used for additional torches provided in the same system described herein (eg, in an external welding system).

Description of drawings

Figure 1 shows a perspective view of a system for welding two pipes according to an embodiment of the present patent application;

Figure 2 shows another perspective view of the system of Figure 1 with the torch and torch mounting system not shown for clarity;

Figure 3 shows a perspective view of one of the two pipe clamps of the system according to an embodiment of the present patent application, wherein the pipe clamp is in its closed position;

Figure 4 shows a perspective view of the pipe clamp of Figure 3 in its open position;

5 and 6 show partial cross-sectional views of the pipe clamp of FIG. 3 with the actuator and clamp slider in their retracted positions in FIG. 5 and the actuator and clamp slider in FIG. 6 its extended position;

7 and 8 illustrate cross-sectional views of a locking mechanism configured to lock a pivotable/movable portion of a pipe clamp according to an embodiment of the present patent application, wherein the locking mechanism is in a released position in FIG. 7 and in in the locked position in Figure 8;

Figures 9, 10 and 11 show cross-sectional views of a locking mechanism configured to lock the pivotable/movable portion of the pipe clamp and the actuator according to another embodiment of the present patent application The pivotable/movable part of the , wherein the locking mechanism is in the released position in Figure 9 and in the locked position in Figures 10 and 11;

Figure 12 shows a perspective view of one of the two pipe clamps of a system according to another embodiment of the present patent application, wherein the pipe clamp is in its closed position;

Figure 13 shows a perspective view of the pipe clamp of Figure 12 in its open position;

14 and 15 show partial cross-sectional views of the pipe clamp of FIG. 12 with the actuator and clamp slider in their retracted positions in FIG. 14 and the actuator and clamp slider in FIG. 15 its extended position;

16 and 17 show partial cross-sectional views of the pipe clamp of FIG. 12 showing an interlock mechanism between clamp sliders according to an embodiment of the present patent application;

Figures 18 and 19 show the torch mounting system with the torch mounting system in its closed position in Figure 18 and the torch mounting system in its open position in Figure 19;

Figure 20 shows a partial perspective view of the torch mounting system of Figure 18;

Figure 21 shows a welding torch in a welding position according to an embodiment of the present patent application;

Figure 22 shows a welding torch positioned radially away from a tube according to an embodiment of the present patent application;

Figure 23 shows the torch in the leftmost axial position according to an embodiment of the present patent application;

Figure 24 shows a welding torch in a welding position according to an embodiment of the present patent application;

Figure 25 shows the torch in the rightmost axial position according to an embodiment of the present patent application;

Figure 26 shows the torch in a left tilted position according to an embodiment of the present patent application;

Figure 27 shows a welding torch in a welding position according to an embodiment of the present patent application;

Figure 28 shows the torch in a tilted right position according to an embodiment of the present patent application;

29 shows a partial cross-sectional view of a system according to an embodiment of the present patent application, showing a torch module, with some components of the system not shown for clarity;

Figure 30 shows a perspective view of the system with the grinder positioned at the start of the weld and the torch partially passing through the weld bead, and with some components of the system not shown for clarity;

Figure 31 shows a perspective view of a system according to an embodiment of the present patent application showing a radial and axial positioning system for a grinder;

32 shows a perspective view of a system according to an embodiment of the present patent application showing a radial positioning system for a grinder.

Figure 33 shows a perspective view of a system according to an embodiment of the present patent application showing an axial positioning system for a grinder;

Figures 34, 35 and 36 illustrate different grinding media that may be used in a grinder according to embodiments of the present patent application;

37 shows a perspective view of an enclosure configured to encapsulate an interface region between a torch, a pipe clamp, and a pipe, according to an embodiment of the present patent application;

Figure 38 shows a perspective view of an enclosure with its walls in an at least partially open position, according to an embodiment of the present patent application;

Figure 39 shows a perspective view of an enclosure with its walls in an at least partially open position with some components removed to more clearly show the enclosure's frame;

Figure 39A shows a partial perspective view of the enclosure with some components removed to more clearly show other portions of the enclosure;

40 and 41 illustrate perspective and partial cross-sectional views of a welding enclosure configured to enclose a welding torch and a torch module in accordance with embodiments of the present patent application;

42-45 illustrate various deployment systems for deploying systems in accordance with embodiments of the present patent application;

Figure 46 shows a prior art system for aligning pipe ends;

47 illustrates a system for aligning tube corners according to embodiments of the present patent application;

Figures 48 and 49 illustrate the angular misalignment between pipe ends (at welded joints) before and after using the system for aligning pipe corners, according to embodiments of the present patent application;

Figure 50 shows a switch trigger mounted on a rail channel according to an embodiment of the present patent application;

Figures 51 and 52 illustrate a switch trigger mounted on a rail channel and a corresponding limit switch mounted on a carriage in accordance with embodiments of the present patent application, wherein Figure 52 illustrates the switch trigger engaged limit switch, and Figure 51 shows the limit switch not engaged with the switch trigger;

Figures 53 and 54 show the system of the present patent application wherein the inspection camera is co-mounted with the inspection detector such that the inspection camera is aimed at the same point on the outer surface of the tube as the inspection detector, also shown in Figures 53 and 54 so that the arc angle between the joint position measured by the inspection detector and the joint position welded by the torch is constant; and

55-59 illustrate guides for an enclosure that keep the system centered over the tube when the enclosure is lowered or raised, according to embodiments of the present patent application.

Detailed ways

1 and 2 show a system 10 for welding two pipes 12 and 14. The system 10 includes a first pipe clamp 16, a second pipe clamp 18, and a welding torch 20 (shown in Figures 21-27). In one embodiment, as shown in FIGS. 30-33 , the system 10 also includes an inspection detector 22 , a motor 24 , one or more processors 26 and a grinder 30 .

In one embodiment, the first tube clip 16 is configured to engage the outer surface 32 of the first tube 12 to enable the first clip 16 to be secured relative to the first tube 12 . In one embodiment, the second tube clip 18 is configured to engage the outer surface 34 of the second tube 14 to enable the second tube clip 18 to be secured relative to the second tube 14 .

In one embodiment, the welding torch 20 is configured to form a welded joint 36 ( FIGS. 21 and 24 ) between the tubes at the interface region 38 ( FIGS. 21 and 24 ) between the tubes 12 and 14 . In one embodiment, inspection detector 22 is configured to emit a beam of inspection radiation. In one embodiment, the motor 24 is operably associated with the inspection detector 22 to direct the inspection radiation beam along the welded joint 36 between the tubes 12 and 14 . One or more processors 26 are operatively associated with the inspection detector 22 to determine the profile of the welded joint 36 between the tubes 12 and 14 . The grinder 30 is configured to grind at least a portion of the welded joint 36 between the tubes 12 and 14 based on the contour of the welded joint 36 between the tubes 12 and 14 .

The term "profile" as used herein is a generic term used to refer to the physical properties of welded joints between pipes. The term "profile data" refers to data corresponding to a profile, which may be obtained from a welded joint. Such data can be obtained, for example, by scanning the welded joint with an inspection detector, such as a laser. Profile data may contain many types of information about profiles, such different types of information are referred to herein as "properties". In one embodiment, the physical properties of the welded joint between the tubes may include, for example, one or more of the following: weld shape, weld height, weld symmetry, weld width, weld color, and/or weld smoothness.

In one embodiment, the tubes 12, 14 may be interchangeably referred to herein as tube segments or tube sections.

In one embodiment, the first tube 12 and the second tube 14 are made of metallic material. In one embodiment, the first tube 12 and the second tube 14 are made of carbon steel material. In one embodiment, the first tube 12 and the second tube 14 are made of an alloy steel material. In one embodiment, the first tube 12 and the second tube 14 are made of a low alloy steel material. In one embodiment, the first tube 12 and the second tube 14 are fabricated (eg, fully or partially) from a corrosion resistant alloy (CRA) material. In one embodiment, the CRA material may include iron-based alloys, such as various grades of stainless steel or nickel-based alloys (ie, commonly known under the trade name Inconel). In one embodiment, the first tube 12 and the second tube 14 may be made of American Petroleum Institute Specification (API) 5L grade X52 (ie, 52000 PSI minimum yield strength and 66000 PSI minimum tensile strength) material. In one embodiment, the first tube 12 and the second tube 14 may be made of API 5L grade X60 (ie, 60,000 PSI minimum yield strength and 75,000 PSI minimum tensile strength) material.

In one embodiment, the first tube 12 and the second tube 14 may be made of the same material. In one embodiment, the first tube 12 and the second tube 14 may be made of different materials. In one embodiment, the first tube 12 and the second tube 14 may be made of bimetallic material. In one embodiment, the inner portion of the tube is made of carbon steel material and the outer portion is made of CRA material. In another embodiment, the inner portion of the tube is a CRA material, and the outer portion of the tube may be a carbon steel material or a different CRA material than the inner portion.

In one embodiment, the first tube 12 and the second tube 14 each have a length of at least 10 feet. In one embodiment, the first tube 12 and the second tube 14 each have a length in the range of about 10 to about 100,000,000 feet. In one embodiment, the first tube 12 and the second tube 14 have an outer diameter of 60 inches or less. In one embodiment, the outer diameter of the pipe segment may also be referred to as the outer diameter of the pipe segment. In one embodiment, the first tube 12 and the second tube 14 each have an outer diameter in the range of about 8 to about 10 inches.

In one embodiment, the system 10 is an external welding system that is generally configured to weld the tubes 12 and 14 from the outside of the tubes 12 , 14 . In one embodiment, the external welding system may be configured to provide shielding gas on the outside of the pipes 12, 14 to be welded (eg, at the joints).

In one embodiment, the external welding system may include a welding material consuming device. In one embodiment, the welding torch 20 is constructed and arranged to feed or guide a consumable wire electrode into the welding area/zone. For example, a wire feeder and reel 187 are shown in FIG. 30 . The consumable wire is provided by a source (eg, a wire spool or wire spool) through a wire feed system. In one embodiment, torch 20 is constructed and arranged to be connected to a power source (eg, a constant voltage power source). In one embodiment, an electric arc is formed between the consumable wire electrode and the tubes 12, 14, which heats the wire and the tubes 12, 14 to melt and join. In one embodiment, along with the consumable wire electrode, a shielding gas is fed through the torch 20 which shields the welding procedure from airborne contaminants. In one embodiment, shielding gas is fed to the welding area/zone through a torch nozzle, which may include a gas cup. In one embodiment, the electrodes may extend beyond the end of the gas cup. In one embodiment, shielding gas stored in system 10 is directed to a wire feed assembly through a hose/shielding gas line for distribution to torch 20 .

As used herein, the term "interface region" refers to the surface of the tubes 12, 14 to be welded in that region, and optionally in the vicinity of the region where the welding material will be deposited. If such a bevel is provided, the interface region comprises at least a part of the bevel of the two pipes to be welded, or alternatively the entire bevel. In one embodiment, if a bevel is provided, the interface region includes the entire bevel surface and also extends beyond the bevel surface. In one embodiment, the interface region 38 is an annular interface region. In one embodiment, the interface region 38 is on the exterior of the tubes 12, 14 at the region of the tubes 12, 14 adjacent to where the welding will take place.

In one embodiment, the ends of tubes 12 and 14 are joined together to form a weld groove therebetween. In one embodiment, the weld grooves may have a V-shaped cross-sectional configuration, a U-shaped cross-sectional configuration, or other shaped cross-sectional configurations, as will be understood by those skilled in the art. In one embodiment, the ends of tubes 12 and 14 may include beveled surfaces. In one embodiment, the welding material is configured to connect the first tube 12 and the second tube 14 .

In one embodiment, the weld joint 36 is a complete circumferential weld of the circumferential end-to-end connecting tubes 12 and 14 . In one embodiment, tubes 12 and 14 are welded together at their beveled ends.

In one embodiment, the weld joint 36 may comprise multiple layers of weld material disposed on top of each other in a radially outward direction. In one embodiment, the multilayered weld material may be referred to as a weld bead layer. In one embodiment, different weld beads or layers may be formed sequentially from the outside/outside of tubes 12 and 14 by external welding system 10 . The weld bead layer may be interchangeably referred to herein as the channel layer. In one embodiment, a weld pass (eg, a root pass, hot pass, filler pass, cap pass) may be a single advancement of the welding tool or welding system 10 along the weld joint 36 . In one embodiment, a weld bead or layer is formed due to each weld bead.

The term "pipe clamp" as used herein may refer to a clamp structure for fixedly securing to a surface of a pipe (eg, the respective outer surfaces 32, 34 of the pipes 12, 14). For example, the clamps may include one or more clamp slides 52 or other support structures configured to interface with the surfaces of the tubes (eg, the respective outer surfaces 32, 34 of the tubes 12, 14). ) engages securely to prevent it from moving.

In one embodiment, the pipe clamp may be a toggle clamp, the structure and operation of this type of clamp is shown in and described with respect to FIGS. 3-11 . In another embodiment, the pipe clamp may be a conical clamp, the structure and operation of which is shown in and described with respect to FIGS. 12-17 .

3 and 4 show the first pipe clamp 16 . The second clamp 18 is a mirror image of the first pipe clamp 16 . In one embodiment, the structure and operation of the second pipe clamp 18 is the same as that of the first pipe clamp 16, and thus the structure and operation of the second pipe clamp 18 will not be described in detail here.

In one embodiment, the clamps 16 and 18 of the external welding system 10 may individually or together be referred to as a braking system of the external welding system 10 , which secures the external welding system 10 in a desired position on the pipes 12 , 14 . In one embodiment, the clamps 16, 18 are radially extending clamps that engage the outer surfaces of the tubes 12 and 14, respectively, to secure the outer welding system 10 from movement.

In one embodiment, each of the first and second pipe clamps 16 and 18 includes a non-pivoting (or fixed) portion 44 , 44 a or 44 b and two pivoting or movable portions 46 , 46 a or 46 b and 48 , 48a or 48b. In one embodiment, the non-pivoting portion 44 is positioned on the top portion of the clamp, and two pivoting or movable portions 46 and 48 are positioned on each side of the non-pivoting portion 44 .

In one embodiment, as shown in FIGS. 1 and 2 , the top stationary/non-pivoting portions 44 of the first clamp 16 and the second clamp 18 may each include a lift point 287 . In one embodiment, the first clamp 16 and the second clamp 18 can each be lifted from one position to another by a lift point 287 to provide an easily removable clamp. In one embodiment, the first clamp 16 and the second clamp 18 may be lifted and moved from one location to another using an overhead crane or similar lifting mechanism and by attaching cables to the lift points 287 . In one embodiment, the first clamp 16 and the second clamp 18 can each be lifted for placement on or removal from the pipe.

In one embodiment, the two pivoting or movable parts of the clamp are configured to allow the clamp to be placed on the corresponding tube. That is, the two pivoting or movable portions 46 and 48 are configured to be hinged (eg, about the pivot pin 68) such that the pivoting or movable portions 46 and 48 swing open to allow the clamp to be placed in the corresponding on the tube and removed from the corresponding tube. In one embodiment, linear actuators 50, 50a, 50b, 50c, or 50d are used to control the position of each pivoting or movable portion 46 and 48 of the clamp. For example, as shown in FIGS. 3 and 4, actuator 50a is used to control the position of the pivoting or movable portion 46 of the clamp, and actuator 50c is used to control the position of the pivoting or movable portion 48 of the clamp. In one embodiment, the actuator 50 may be a hydraulic cylinder/actuator, a pneumatic cylinder/actuator, an electric actuator, or any other actuator, as will be understood by those skilled in the art.

In one embodiment, the first clamp 16 and the second clamp 18 may be connected to each other using guide members or rods 40 . In one embodiment, as shown in Figures 1 and 2, the first clamp 16 and the second clamp 18 are connected to each other using four guide rods 40a-d.

Two of the four guide rods 40a and 40b are configured to connect the non-pivotable portions 44a and 44b of the first clamp 16 and the second clamp 18 to each other. In one embodiment, the two non-pivotable guide rods 44, 44a or 44b are also configured to support the guide rail member 88 (shown in and described in relation to FIGS. 18 and 19), so The rail members are configured to support the torch module 126 (including the torch 20 ), the grinder module (including the grinder 30 ), and the inspection module (including the inspection detector 22 and/or the inspection camera 182 ) thereon.

The remaining two guide rods 40c and 40d (of the four) are configured to connect each of the two pivotable portions 46a and 48a of the first clamp 16 with the corresponding pivotable portions 46b and 48b of the second clamp 18 connect. In one embodiment, the guide rod 40c is configured to connect the pivotable portion 46a of the first clamp 16 with the corresponding pivotable portion 46b of the second clamp 18 . In one embodiment, the guide rod 40d is configured to connect the pivotable portion 48a of the first clamp 16 with the corresponding pivotable portion 48b of the second clamp 18 .

Figure 3 shows the two bottom pivotable parts 46 and 48 of the clamp in a closed (and locked) position, while Figure 4 shows the two bottom pivotable parts 46 and 48 of the clamp in a swing open position. That is, the two bottom pivotable portions 46 and 48 of the clamp may be adapted to pivot radially outward so that the clamp may swing open to allow the tube to be positioned below the non-pivotable portion 44 . When the tube is in place, the two bottom pivotable parts 46 and 48 of the clamp can swing into the locked position.

In one embodiment, the first procedure of pipe welding (ie, welding two pipes together) is a pipe holding procedure. In one embodiment, the two tubes 12, 14 are held in the correct position for welding during the tube holding procedure. In one embodiment, the tube holding procedure may include a tube forming procedure and a tube alignment procedure. In one embodiment, the tube forming procedure and the tube alignment procedure are performed by the first and second tube clamps 16 and 18 .

In one embodiment, the tube forming procedure and the tube alignment procedure are not separate, and these procedures always occur simultaneously. In one embodiment, the tube forming procedure cannot be completed without the tube alignment procedure, and vice versa.

In one embodiment, each tube clamp 16, 18 is configured to perform both a tube forming procedure and a tube alignment procedure. In one embodiment, the tube forming procedure is optional, and each tube clamp 16, 18 is configured to perform only the tube alignment procedure.

During the tube forming procedure, the two tubes 12, 14 to be welded together are made to have the same shape. This can be achieved by using pipe clamps 16 , 18 for the respective pipes 12 , 14 . In one embodiment, as will be explained in detail below with respect to FIGS. 3-17 , each pipe clamp 16 , 18 includes a series of mechanically connected gripper/clamp slides 52 that are configured and are arranged to move radially inward towards the corresponding tubes 12 , 14 . The mechanical links connecting adjacent gripper/clamp slides 52 are constructed and arranged to ensure that all gripper/clamp slides 52 are always the same radius.

In the tube alignment procedure, the two tubes 12, 14 to be welded together are aligned so that the centerlines of the two tubes are coaxial. In one embodiment, the two tubes are also aligned such that the space between the two tubes is set to a predetermined distance. In one embodiment, the predetermined distance may vary from 0 inches (ie, two tubes 12, 14 in contact with each other) to a small gap. In one embodiment, the small gap does not exceed 0.065 inches. In one embodiment, the two tubes 12, 14 may be drawn together to create a compressive force between the two tube faces to minimize movement of the welded joint 36 during welding.

In one embodiment, the tube alignment procedure may further include a tube center alignment procedure and a tube face alignment procedure. In one embodiment, during the tube centering procedure, the two clamps 16 and 18 are connected via a plurality of guide rods 40a-d such that the geometric centers of the two sets of clamp/clamp slides 52 are coaxial.

During the pipe face alignment procedure, in one embodiment, the first pipe clamp 16 and the second pipe clamp 18 are configured to be movable relative to the other of the first pipe clamp 16 and the second pipe clamp 18 to control the Axial play between tubes 12 and 14. That is, one of the clamps 16 and 18 is configured to slide along the plurality of guide rods 40 , 40a - d to vary the axial distance between the two sets of clamp/clamp slides 52 . If this alignment is performed while the clamps hold the respective tubes 12 and 14, the distance between the tubes 12 and 14 also changes. In one embodiment, the distance between clamps 16 and 18 is controlled by two actuators 42 (shown in Figures 1 and 2). An actuator 42 is positioned on each side of the tubes 12 and 14 . In one embodiment, the actuator 42 may be a hydraulic cylinder/actuator, a pneumatic cylinder/actuator, an electric actuator, or any other actuator, as will be understood by those skilled in the art.

In one embodiment, one of the first pipe clamp 16 and the second pipe clamp 18 is configured to be movable relative to the other of the first pipe clamp 16 and the second pipe clamp 18 so as to be positioned between the pipes 12 , 14 Axial compressive force is generated between them.

In one embodiment, by using an external crane 190 to lift the welded joint, the pipe corners of the pipes 12, 14 can be aligned relative to each other at the welded joint. For example, in one embodiment, the first pipe clamp 16 and the second pipe clamp 18 are lifted from one welded joint to the next by an external crane 190 . Since the external crane 190 is configured to remain connected to the first pipe clamp 16 and the second pipe clamp 18 at all times, the external crane 190 can be used to apply a net load to the pipes 12 and 14 to change their relative angles at the welded joint.

Prior art methods for aligning pipe ends typically require the new pipe 186 to be held by a sidearm pipelayer 188 or other lifting equipment for the entire duration of the root pass weld plus the initiation of the second (hot) pass weld . As each tube is welded, tube supports 184 are placed near the free ends. The weight of the tubes causes them to sag between the tube supports 184 . This sagging forces the free end of the tube to slope upward. For example, Figure 46 shows tube deflection between tubes using this prior art method. In order to have a consistent welded joint profile, the pipe ends must be aligned in vertical, horizontal and axial directions as well as in pitch and yaw. In prior art methods, to align the unwelded pipe 186 with the previously welded pipe, the unwelded pipe 186 was held in place using a sidearm pipelayer 188 to hold the two pipe ends in place and angle alignment.

FIG. 47 shows the system of the present patent application configured to align the pipe corners of the pipe relative to each other by lifting the welded joint by the external crane 190 . The system of the present patent application allows the sidearm pipelayer 188 to place the unwelded pipe 186 near the correct alignment and then proceed with other activities without having to wait for the first weld pass (eg, the root pass) to be 100% complete . In some embodiments, the sidearm pipelayer 188 may be moved before the start of the first weld pass. Referring to Figures 47-49, the method of the present patent application begins with placing a pipe support 184 near the middle of each pipe section rather than near one end. This allows the ends of two adjacent tubes to sag by a similar distance and angle. Once the system of this patent application has been closed around the pipe, the system can be lifted by an external crane 190 to change the local deflection and angle at the welded joint. As can be appreciated by those skilled in the art, the lift direction need not be in a perfectly vertical direction, but can be any angle required to improve the alignment of the two pipe ends. Therefore, this alignment method allows a small gap between the two tubes for the first (root) pass. That is, with the external crane 190 capable of controlling the angular alignment of the two tubes 12, 14, the two tubes 12, 14 do not need to be in contact to ensure proper angular alignment. This makes it possible to use an axial actuator between the two clamps to control the relative axial position of the two tubes 12 , 14 so that there is a small gap at the interface between the tubes 12 , 14 . As will be understood by those skilled in the art, by appropriately adjusting the crane 190, the gap at the interface between the two tubes 12, 14 can be made uniform to within a small tolerance (eg, less than 10% at all points along the interface) ).

One of the reasons for being able to preload the tubes 12, 14 with the slide clamps 16, 18 is to be able to resist the bending forces that would normally be used to create a gap on one side of a welded joint. These bending forces can be controlled by adjusting the vertical load from the external crane 190 configured to lift the envelope 200 . In one embodiment, once the clamps 16 , 18 have engaged the pipes 12 , 14 , the crane 190 is configured to pull with a force greater or less than the weight of the system to create a vertical load on the pipes 12 , 14 . If this vertical load is properly controlled, any bending forces at the welded joint can be reduced and possibly eliminated.

Figures 48 and 49 show a comparison of the angular misalignment between the tubes before and after the system of the present patent application is lifted to change the local deflection and angle at the welded joint.

Referring to FIGS. 5 and 6 , in one embodiment, each pipe clamp 16 or 18 includes a plurality of clamp slides 52 configured to clamp/engage the corresponding pipe 12 , 14 . In one embodiment, the clamp slider 52 can have different heights for different sized tubes and can be fine-tuned, eg, with spacers or any other adjustment member. In one embodiment, the size (ie, outer diameter) of each tube has a corresponding clamp slider size. In one embodiment, the clamp slides 52 are interchangeable for different tube sizes. In one embodiment, the clamp slide 52 may be a self-centering member.

In one embodiment, each clamp slide 52 includes a tube surface contacting member (or surface). In one embodiment, the tube surface contacting members are constructed and arranged to frictionally engage the outer/outside surfaces 32, 14 of the tubes 12, 14 on either side of the interface region 38 between the tubes 12, 14 when the clamps 16, 18 are extended. 34.

In one embodiment, each clamp slider 52 is constructed and arranged to be connected to and positioned on its associated clamp slider pin member 54 . In one embodiment, the clamp slider pin member 54 is constructed and arranged to extend through its corresponding opening 56 in the housing member 58 . In one embodiment, the openings 56 in the housing member 58 are constructed and arranged to extend generally radially in the housing member 58 to enable the clamp slider pin members 54 in corresponding openings 56 in the housing member 58 Radial movement (eg, up and down radial movement). In one embodiment, the housing member 58 may be any member constructed and arranged to facilitate movement of the clamp slider pin member 54 such that the clamp exerts a clamping force on the outer/exterior surfaces of the tubes 12 , 14 .

In one embodiment, one end of the clamp slider pin member 54 is attached to the clamp slider 52 and the other end of the clamp slider pin member 54 is connected to the connecting member 60 . In one embodiment, the end of the clamp slider pin member 54 includes a notch constructed and arranged to receive the connecting member 60 therein. In one embodiment, the end of the clamp slider pin member 54 further includes an opening constructed and arranged to receive a fastening member to connect the connection member 60 to the end of the clamp slider pin member 54 .

In one embodiment, the housing member 58 may include an opening constructed and arranged to effect connection between the clamp slider pin member 54 and the linkage member 60 . In one embodiment, the opening of the housing member 58 is also constructed and arranged to enable movement of the connecting member 60 as the clamp moves between its retracted and extended positions. In one embodiment, the connecting member 60 is an elongated member having an opening formed at its end portion. In one embodiment, the end portion of the connecting member 60 has a generally circular configuration to enable movement of the connecting member 60 as the clamp moves between its retracted and extended positions.

In one embodiment, one end of the connecting member 60 is connected to the clamp slider pin member 54 and the other end of the connecting member 60 is connected to the actuator member 62 . In one embodiment, each clamp slide 52 is thus connected to the actuator member 62 via its associated clamp slide pin member 54 and connecting member 60 .

In one embodiment, the actuator member 62 may include a recess constructed and arranged to effect a connection between the connection member 60 and the actuator member 62 . In one embodiment, the recess of the actuator member 62 is also constructed and arranged to effect movement of the connecting member 60 in the recess as the clamp moves between its retracted and extended positions.

In one embodiment, the actuator member 62 is constructed and arranged to connect to a portion of the actuator 64 . In one embodiment, the actuator may be a hydraulic cylinder/actuator, a pneumatic cylinder/actuator, an electric actuator, or any other actuator, as will be understood by those skilled in the art. In one embodiment, the actuating member 62 is configured to move axially relative to the clamp housing. The position of the actuating member 62 may be controlled by a plurality of actuators 64 connected to the clamp housing.

In one embodiment, the actuating member 62 is held centrally on the clamp housing by a plurality of guide rods 66 (shown in FIGS. 3 and 4 ). The two guide rods 68 also serve as pivot points for the hinged segments 46 and 48 . In this way, the housing segments 46 and 48 and the actuating member segment pivot about the same point and maintain their relative orientation at all times.

The clamp is moved from a retracted position (shown in FIG. 5 ) in which the clamp is not in contact with the outer surfaces of the tubes 12 , 14 to a position where the clamp is configured to apply a clamping force on the outside of the tubes 12 , 14 by actuation of the actuator 64 . The extended position on the surface (as shown in Figure 6). In one embodiment, axial movement of portions of actuator 64 in turn causes axial movement of actuation member 62 . In one embodiment, axial movement of the actuating members 62 is translated into radial movement of the clamp slider pin members 54 via their connecting members 60 . Thus, the radial clamping force is generated by the actuator 64 driving the connecting member 60 , which converts axial movement of the actuator into radial movement of the clamp slide 52 .

In one embodiment, the size of the actuator's air cylinder, the applied fluid pressure, and the size of the various components of the clamps can be varied to control the clamping force the clamps exert on the outer surfaces of the tubes 12 , 14 .

In one embodiment, the actuating member 62, the connecting member 60, the slider pin member 54, and the clamp slider 52 are all sized so that when the actuating member 62 is retracted there is a gap between the clamp slider 52 and the tube Small clearance, and a small angle between the axis of the connecting member 60 and the slider pin member 54 when the actuating member 62 is engaged. In one embodiment, this smaller angle greatly amplifies the force generated by actuator 64 . The radial force on the tube at the gripper slide may be 10 times greater than the force produced by the actuator.

In one embodiment, the one or more processors 26 are configured to modify the interface area 38 between the pipes 12, 14 by actuating the first pipe clamp 16 and/or the second pipe clamp 18 prior to the welding operation to be based on Predetermined data (eg, pre-weld profile data for the interface region 38 ) to vary the roundness (or ovality) of the first tube 12 and/or the second tube 14 . For example, in one embodiment, the one or more processors 26 are configured to alter the gap between the tubes 12, 14 by selectively actuating one or more clamp sliders 52 of the clamps 16 and/or 18 prior to a welding operation interface area 38 to vary the roundness of the first tube 12 and/or the second tube 16 based on the pre-weld profile data. In one embodiment, the minimum number of clamp slides 52 is three. The number of clamp slides 52 may vary in other embodiments.

In one embodiment, all the gripper slides of the first gripper always move together. In one embodiment, all the gripper slides of the second gripper always move together. In one embodiment, each clamp is constructed and configured such that all its associated clamp slides always move together.

For example, the clamping force may slightly alter the distance between the pipe ends and/or the relative radial displacement between the pipe ends at some (or all) of the interface region 38 . Additionally, the clamping force applied by the clamps can alter the roundness of one or both tubes (eg, a first clamp can alter the roundness of a first tube to be welded and/or a second clamp can alter a second tube to be welded roundness). That is, changing the shape of a slightly out-of-round tube to a more round tube. In one embodiment, for example, the clamp slides 52 for either of the clamps 16, 18 are symmetrically positioned and evenly spaced circumferentially around the exterior of the engaged tube. Additionally, the innermost surface of each clamp slide may be equidistantly spaced from the center axis of the clamp. Due to the possibility of shape change, the profile of the interface region is not fully defined until full clamping force is applied by both clamps. The inspection detectors described herein can be used to determine the profile of the interface area and/or the welded joint after clamping has been applied.

In one embodiment, a larger clamping force is used to open the two pivoting clamp segments 46 and 48 of the clamp. In one embodiment, each clamp may include a latch mechanism 100 configured to hold the clamp (ie, its pivotable/movable portion) in a closed position on the tube. In one embodiment, two locking pins are used to hold the pivoting clamp segments 46 and 48 together. In another embodiment, the two pivot clamp segments 46 and 48 overlap at the interface where the two pivot clamp segments 46 and 48 meet. There is a concentric hole through the two overlapping sections. In one embodiment, a movable pin or locking member 70 is located in one hole 72 and is configured to be actuated to extend from the hole 72 into a second hole 74, as shown in FIGS. 7 and 8 . The movable pin member 70 is in its retracted position in FIG. 7 and in its extended position in FIG. 8 .

In one embodiment, the actuation member 62 of the clamp is also divided into three sections. Each segment of the actuation member 62 corresponds to one of the three clamp housing segments 44 , 46 and 48 . In one embodiment, like clamp housing segments 46 and 48, at the interface where the two pivot actuation member segments come into contact, the two segments of the pivot actuation member segment also overlap. In one embodiment, there is a concentric hole through the two overlapping portions.

In one embodiment, referring to Figures 9-10, the movable pin or locking member 76 is positioned such that when the clamp is closed, the movable pin 76 can be actuated to pass through the hole in the overlapping portion. In one embodiment, the pin actuator may make additional travel remaining after the two actuation ring segments have been locked together by the pin member 76 . In this way, the pin member 76 can move with the actuation member 62 when the actuation member 62 is engaged. The movable pin member 76 is in its retracted position in FIG. 9 and in its extended position in FIG. 10 . Figure 10 shows the movable pin member 76 in its extended position and the actuator member 62 in its disengaged position, and Figure 11 shows the movable pin member 76 in its extended position and its engaged position Actuator member 62 . Comparing Figures 10 and 11, it can be clearly seen that the pin actuator has additional travel remaining after the two actuation ring segments have been locked together by the pin member 76 (in Figure 10). This additional travel of the pin actuator remaining after the two actuation ring segments have been locked allows the pin member 76 to move with the actuating member 62 as the actuating member 62 is actuated from its retracted position to its engaged position .

Figures 12-17 illustrate another embodiment of a clamp 16' or 18'. In one embodiment, the structure and operation of the clamp of Figures 12-17 is similar to that of the clamp of Figures 3-11, with the exceptions noted below.

The clamp 16' or 18' of Figures 12-17 is also divided into three parts: a top fixed/non-pivoting part 44' and two bottom pivotable parts 46' and 48'. The two bottom pivotable portions 46' and 48' are hinged so that the two bottom pivotable portions 46' and 48' can swing open to allow the clamp to be placed and removed from the tube. In one embodiment, linear actuators are used to control the position of each movable/pivotable clamp portion. In one embodiment, the actuator is an electrical actuator. Figure 12 shows the two bottom pivotable portions 46' and 48' of the clamp in a closed (and locked) position, while Figure 13 shows the two bottom pivotable portions 46' and 48' of the clamp in a swinging open Location. That is, the two bottom pivotable portions 46' and 48' of the clamp may be adapted to pivot radially outward so that the clamp may swing open to allow the tube to be positioned below the non-pivotable portion 44'. When the tube is in place, the two bottom pivotable portions 46' and 48' of the clamp can swing into a closed (and locked) position.

In one embodiment, the gripper 16' or 18' includes a plurality of gripper slides 52' (eg, 4 or more gripper slides) to grip and shape the tube. In one embodiment, the clamp slides 52' are interchangeable for different sized tubes. In one embodiment, each tube size has a corresponding slider size. In one embodiment, the clamp slide 52 ′ is mounted in the angled guide 78 . In one embodiment, the angled guide 78 is fixedly attached to the clamp housing. As shown in FIGS. 14 and 16 , when the clamp slider 52 ′ is positioned at one end 80 of the angled guide 78 , the clamp slider 52 ′ is in its retracted position. As shown in FIGS. 15 and 17 , when the clamp slider 52 ′ is positioned at the other end 82 of the angled guide 78 , the clamp slider 52 ′ is in its engaged position. The angled guide 78 is constructed and arranged to taper downwardly from end 80 to end 82 . In one embodiment, each clamp slide 52' is angled along its respective between end 80 and end 82 by a linear actuator 64' (eg, hydraulic, pneumatic, or electric) The guide 78 moves.

In one embodiment, as shown in Figures 16 and 17, the clamp slides 52' have interlocking features to ensure that all clamp slides 52' travel the same distance along their respective angled guides/tracks, And thus all clamp slides 52' are at the same distance from the center of the tube. In one embodiment, this interlocking connection may also be referred to as a "tongue and fork". In one embodiment, when the clamp sliders 52' are actuated and moved closer together, the tongues 84 of the clamp sliders 52' are configured to slide to interlock with the prongs 86 of the adjacent sliders 52" Connection. In one embodiment, each clamp slider 52" includes a tongue 84 on one end portion and a fork 86 on the other end portion.

In yet another embodiment, the clamp may be a saber clamp. Such a saber clamp is described in detail, for example, in U.S. Patent No. 6,109,503, which is incorporated by reference in its entirety into this patent application.

In one embodiment, the system 10 may also include a sensing system configured to monitor the clamping force generated by the clamp so that the clamp does not generate a clamping force to compress the tube or cause permanent deformation of the tube. In another embodiment, the sensing system is optional.

In one embodiment, permanent deformation of the tube can be avoided by limiting the pressure used to actuate the clamp. The pressure limit is a function of tube yield strength, tube diameter and tube wall thickness. In one embodiment, the values for tube yield strength, tube diameter and tube wall thickness are entered into one or more processors. The one or more processors are configured to process the received values of tube yield strength, tube diameter and tube wall thickness and calculate the correct pressure value. This calculated pressure value can then be set as the pressure value in the pressure limiting device. In one embodiment, the pressure limiting device is configured to limit the pressure to a set pressure value to actuate the clamp.

In one embodiment, permanent deformation of the tube can be avoided by stopping the clamping once all of the clamp slides are brought into contact with the tube. In order to do this, one or more processors need to know when all the gripper slides have been in contact with the tube. In one embodiment, contact sensors can be used to determine when all of the gripper slides have been in contact with the tube.

In one embodiment, a non-contact sensor, such as a proximity switch, can be mounted to each clamp slide. When the distance between the gripper slide and the tube stops changing, the gripper slide has been brought into contact with the tube. This constant value can be checked against a value recorded from a previous clamping operation or a predetermined target value. This ensures that the clamps have indeed made contact and have not gone through their stroke before making contact.

In one embodiment, a contact switch, such as a single-post, double-throw switch, can be mounted to each clamp slide. In one embodiment, the switch is configured to change state when the clamp slider is in contact with the tube.

In one embodiment, a direct load cell, such as a load cell, or an indirect load cell, such as a strain gauge, may be mounted to each clamp slide. When all sensors report varying non-zero values, then the gripper slides are all in contact with the tube.

In one embodiment, system 10 includes one or more welding torches. In one embodiment, the torch is configured to travel 180 degrees around the tube, 360 degrees around the tube, 720 degrees around the tube, or 1080 degrees around the tube. In one embodiment, the torch may be configured with additional travel to ensure that the welding overlaps the start and end points. In one embodiment, the torch may be configured with additional travel to cover the distance between the joint sensing laser and the torch.

In one embodiment, the torch 20 is configured to apply multiple overlapping weld passes without stopping and restarting. In one embodiment, torch 20 is configured to perform multiple welding processes including, but not limited to, surface tension transfer (STT), metal inert gas (MIG), pulsed MIG, tungsten inert gas (TIG), cold metal transfer CMT ), Pulse Multi Control (PMC) and Low Spatter Control (LSC).

In one embodiment, as shown in FIGS. 18 and 19 , the welding torch 20 is configured to be mounted to a circular rail member 88 . The rail member 88 is configured to be placed/disposed around one of the first tube clip 16 and the second tube clip 18 such that the welding torch 20 is located between the first tube clip 16 and the second tube clip 18 and is in contact with the tubes 12 and 14 The interface region 38 between and/or the welded joint 36 to be welded is on the same line.

In one embodiment, the rail member 88 is divided into three sections: a top fixed/non-pivotable section 90 and two bottom pivotable sections 92 and 94 . The two bottom or side pivotable parts 92 and 94 are configured to be hingedly/pivotably connected to the top fixed/non-pivotable part 90 so that the two pivotable parts 92 and 94 can swing open to allow the rails Member 88 (together with inspection detector 22 and torch 20) is placed on and removed from the tube. In one embodiment, linear actuators 96 may be used to control the position of each movable clamp segment 92 and 94 . In one embodiment, electric, mechanical, hydraulic, pneumatic, or any other type of linear actuator may be used.

In one embodiment, the rail member 88 also includes a latch mechanism 98 configured to retain the rail member 88 in the closed position on the tube. In one embodiment, the structure and configuration of the latch mechanism may be similar to the latch mechanism 100 shown in and described with respect to FIGS. 7 and 8 . In another embodiment, the latch mechanism 98 may have any other structure and/or configuration, as will be appreciated by those skilled in the art.

In one embodiment, as shown in FIG. 1 , the inner diameter of the rail member 88 is configured and sized such that the inner surface 102 of the rail member 88 is positioned about the outer surface 104 of the portion 106 of the clamp 16 or 18 . In one embodiment, the rail member 88 includes two openings 108 on the fixed/non-pivotable portion 90 thereof. In one embodiment, the two openings 108 are configured to receive guide rods 40a and 40b therethrough. In one embodiment, once the system 10 is positioned on the tubes 12, 14, the rail member 88 is configured to lock relative to its associated clamp on which the rail member 88 is mounted, such that the rail member 88 is not present Axial movement relative to its associated gripper.

Figure 18 shows the two bottom pivotable portions 92 and 94 of the rail member 88 in the closed (and locked) position, while Figure 19 shows the two bottom pivotable portions 92 and 94 of the rail member 88 in the swing open Location. That is, the two bottom pivotable portions 92 and 94 of the rail member 88 may be adapted to pivot radially outwardly such that the rail member 88 may swing open to allow the tube to be positioned below the non-pivotable portion. When the tube is in place, the two bottom pivotable portions 92 and 94 of the rail member 88 can swing into the locked position.

In one embodiment, referring to FIG. 20 , the rail member 88 includes a U-shaped channel 110 configuration. In one embodiment, a curved track 112 with an integrated rack and pinion 114 (teeth not shown) is mounted inside the U-shaped channel 110 of the rail member 88 . In one embodiment, the track member 88 also includes an absolute encoder configured to determine all modules (torch modules 126 (including torch 20 ), grinder modules, etc. that are always traveling on the track member 88 . (including the grinder 30) and the exact location of the inspection module (including the inspection detector 22 and/or the inspection camera 182). In one embodiment, an absolute encoder is built into the rail member 88 . In one embodiment, the encoder is optional.

In one embodiment, the welding torch 20 may include one or more absolute position encoders. In one embodiment, the absolute position encoder is configured to determine the position and/or orientation of the welding torch 20 along each of three mutually perpendicular axes (eg, the X-axis, the Y-axis, and the Z-axis). In one embodiment, the welding torch 20 may include three absolute position encoders, each configured to determine the welding torch 20 along three mutually perpendicular axes (eg, the X-axis, the Y-axis, and the Z-axis ) position and/or orientation.

In one embodiment, the system 10 also includes one or more torch motors. In one embodiment, one or more processors 26 of system 10 are configured to control one or more torch motors to control the position and/or orientation of welding torch 20 .

In one embodiment, the torch 20 is operably connected to a torch motor. In one embodiment, the torch motor is operably connected to one or more processors to control the movement of the torch 20 along the welding joint during welding operations. In one embodiment, the torch motor is described in detail in International Patent Application No. PCT/US2015/062558, filed November 24, 2015, which is incorporated by reference in its entirety into this patent application.

In one embodiment, the one or more processors 26 are also configured to interact with the inspection detector 22 and/or the inspection camera 182 to scan the interface area between the tubes 12, 14 for before, during and after the welding procedure Delineation of the interface region between the tubes 12, 14, generating pre-weld profile data, dynamic weld profile data and post-weld profile data based on the scanned data, and based on the generated pre-weld profile data, dynamic weld profile data or weld profile data post profile data to control the external welding system and/or its operation.

In one embodiment, pre-weld inspection, dynamic inspection, and post-weld inspection may be performed by the inspection detector. In another embodiment, pre-weld inspection, dynamic inspection, and post-weld inspection may be performed by inspection detector 22 and inspection camera 182 .

In various embodiments, "pre-weld" profile data as described herein refers to data obtained from an inspection detector (eg, such as by an inspection laser) that has been activated before the welding torch has been activated to begin securing the tubes to each other The interface area between the two tubes to be welded was scanned. This pre-weld profile data is passed to one or more processors to determine whether the tube is sufficiently aligned before depositing any weld material into the interface region. In one embodiment, if misalignment is detected, such as by determining by the one or more processors that the misalignment is outside an acceptable misalignment value, the one or more processors are configured to orient a clamp engaged with the outer surface of the tube send a signal. The clamping force of one or both of the clamps can be adjusted based on the output signal from the pre-weld profile data to adjust the relative shape of the tubes so that the alignment of the interface region is within acceptable misalignment values.

It will be appreciated that, given the slight inconsistency of the tube structure, absolutely perfect alignment is often (and often) not achieved. Nonetheless, such perfect alignment is not necessary as long as the alignment is within tolerances suitable for good welding.

In one embodiment, the pre-weld profile data may include tube ovality/roundness data. In one embodiment, the tube ovality/roundness data may include the location and size of the smallest diameter, the location and size of the largest diameter, the average tube diameter, the average tube wall thickness, the location and size of the smallest wall thickness, and/or the largest Location and size of wall thickness. In one embodiment, the tube ovality/roundness data may include each of the location and size of the smallest diameter, the location and size of the largest diameter, the location and size of the smallest wall thickness, and the location and size of the largest wall thickness with their comparison between the corresponding predetermined values of . In one embodiment, the tube ovality/roundness data may include a comparison between each of the tube mean diameter and the tube mean wall thickness and their corresponding predetermined values. In one embodiment, based on the comparison, the tube ovality/roundness data may include diameter deviations of the tube at all locations on the circumference of the tube.

In one embodiment, the pre-weld profile data may include pipe bevel profile data. In one embodiment, the pipe bevel profile data may include pipe bevel geometry. In one embodiment, the pipe bevel profile data may include the size and shape of the pipe bevel, the root (slope) thickness of the pipe bevel, the bevel angle of the pipe bevel, the offset of the pipe bevel, and the pipe bevel A comparison between each of the root angles of the mouth and their corresponding predetermined values. In one embodiment, based on the comparison, the pipe bevel profile data may include pipe bevel deviations for the pipe at all locations on the circumference of the pipe.

In one embodiment, the pre-weld profile data may include weld joint fit and alignment data. In one embodiment, the weld joint fit and alignment data may include data regarding the gap between the inner abutting ends of the tubes (after tube alignment). In one embodiment, the weld joint fit and alignment data may include data regarding the gap between the grooves of the pipe (after pipe alignment). In one embodiment, the weld joint fit and alignment data may include the location and size of the smallest gap, the location and size of the largest gap, and/or the average gap. In one embodiment, the weld joint fit and alignment data may include a comparison between each of the location and size of the smallest gap and the location and size of the largest gap and their corresponding predetermined values. In one embodiment, the weld joint fit and alignment data may include a comparison between the average gap and its corresponding predetermined value. In one embodiment, based on the comparison, the weld joint fit and alignment data may include the gap deviation of the tube at all locations on the circumference of the tube. In one embodiment, weld joint fit and alignment data may include minimum height differences between tubes (eg, which is an acceptable alignment), and the like.

In one embodiment, the one or more processors are configured to interact with the inspection detector to scan the area of the interface between the tubes to determine, during the welding procedure, the area of the interface before the welding material is deposited thereon, The interface area between the tubes is contoured and dynamic contour data is generated. In one embodiment, the one or more processors are configured to generate welding signals based on the dynamic profile data to control the welding torch. The dynamic profile data is described in detail below. The term "on-the-fly" as used herein also means or refers to "real time", meaning that the welding machine is controlled using sensing or detection by one or more processors during the current welding operation. Of course, since the torch lags the inspection detector/inspection laser by a defined distance, some buffering (or slight time delay) occurs between receiving the profile data and one or more processors using the data to control the torch.

In one embodiment, the one or more processors are configured to interact with the inspection detector 22 and/or the inspection camera 182 to determine the interface area and/or the contour of the welded joint after the welding operation.

In one embodiment, the post-weld profile data may include the profile of the bead formed. In one embodiment, the post-weld profile data may include the profile of the root bead weld layer formed. In one embodiment, post-weld profile data may include weld shape characteristics such as mismatches, bead concavities, and concave corners. In one embodiment, the one or more processors are configured to cause another welding operation to be performed on the interface region between the tubes based on the post-weld profile data. In one embodiment, the repair procedure is configured to repair any weld defects detected during the post-weld inspection procedure. The weld repair procedure described herein can be one of many types. In one embodiment, additional welding operations are performed on top of the previous weld to remedy any weld defects. In another embodiment, the defective weld may be ground by the grinder 30, or alternatively completely cut away (manually or automatically) prior to any subsequent repair welding operations.

In one embodiment, inspection data from inspection detectors may be communicated in real-time to one or more processors using the inspection data to send updated welding parameters to an external welding system.

In one embodiment, the welding head assembly includes: a radial positioning system 116 (shown in Figures 21 and 22) configured to effect radial movement of the welding torch 20; an axial positioning system 118 (shown in Figures 23- 25), which is configured to effect axial movement of the welding torch 20; and a tilt positioning system 120 (shown in FIGS.

In one embodiment, the welding torch 20 is mounted for radial movement by the radial positioning system 116 such that its welding tip is configured to move toward and away from the outer welding surface of the tube. In one embodiment, the one or more processors 26 are configured to control one or more torch motors to adjust the radial distance of the welding tip from the tubes 12 , 14 . In one embodiment, the radial positioning system of the welding torch 20 is configured to retract the welding torch 20 away from the tube to prevent damage when moving from one weld joint to the next.

In one embodiment, the radial positioning system 116 of the welding torch 20 is configured to allow the welding torch 20 to be positioned at the correct height for each weld pass. In one embodiment, as each pass is completed, the torch 20 is moved (by a radial positioning system) away from the center of the tube before the next pass can begin. For example, the one or more processors 26 are configured to control the one or more torch motors to move the welding tip radially away from the interface area after the root pass weld to accommodate the weld material deposited in the root pass weld And provide a hot pass weld on top of the root pass weld.

In one embodiment, the radial positioning system 116 is configured to enable the torch 20 to move radially to track changes in tube shape to adjust the multi-pass welding tip to workpiece (eg, tube) distances (eg, root and Hot Bead Welding Procedure) and retracts from the tube when the welding system is not welding. That is, during each weld pass, the radial positioning system 116 is configured to track the deviation of the tube diameter to maintain a constant distance between the weld joint/interface area between the torch tip and the tube.

In one embodiment, radial positioning system 116 is configured to provide approximately 1.25 inches of radial travel to welding torch 20 . In one embodiment, the torch 20 is movable between a normal non-extended retracted configuration and an extended configuration by the radial positioning system 116 . Referring to Figures 21 and 22, the welding torch 20 has been extended (to its extended configuration) by the radial positioning system 116 so that the welding torch 20 is positioned at the correct/desired/predetermined distance from the tube for the welding procedure. Figure 22 shows the torch 20 moved (by the radial positioning system 116) to a retracted position of the torch 20 away from the tube to prevent damage when moving from one weld joint to the next. Figure 21 shows the welding torch 20 being moved (by the radial positioning system 116) to a welding position where the welding torch 20 is positioned at the correct height for the welding procedure.

In one embodiment, the radial positioning system 116 may include a linear actuator. In one embodiment, the radial positioning system 116 may include a radial torch (electric) motor, a lead screw, and a lead nut. In one embodiment, the motor is configured (eg, mechanically coupled) to rotate the lead screw. In one embodiment, the motor is configured to rotate in a clockwise or counterclockwise direction such that the torch 20 is raised or otherwise substantially parallel to the radial axis R-R of the tubes 12, 14 (shown in FIGS. 21 and 22 ). reduce. In one embodiment, the motor is configured to be directly connected to rotate the lead screw. In another embodiment, the motor is configured to rotate the lead screw connected indirectly, eg, through a series of gears or gearboxes. In one embodiment, the lead screw includes threads machined on its outer surface and extending along its length. In one embodiment, the lead nut is constructed and arranged to be threaded onto the lead screw and includes complementary threads machined on its inner surface. In one embodiment, the lead nut is configured to interlock with a portion of the radial positioning system such that rotation of the lead nut is prevented along with the lead screw. That is, the lead nut is constrained from rotating with the lead screw, so the lead nut is configured to travel up and down the lead screw. In one embodiment, the radial positioning system may also include other components and guides that are configured to transmit rotational movement of the motor into radial movement of the welding torch 20 . For example, when the lead screw is rotated by the motor, the lead nut is driven along the threads. In one embodiment, the direction of movement of the lead nut depends on the direction of rotation of the lead screw of the motor. The radial positioning member is configured to travel/move (up or down) the lead screw with the lead nut when the lead nut is interlocked in the opening of the radial positioning member. The slidable engagement between the radial positioning member and the guide rod member also facilitates this (up or down) travel/movement of the radial positioning member.

In one embodiment, the axial positioning system 118 is configured to enable axial movement of the welding torch 20 to maintain the welding torch 20 in the welding groove and allow the welding torch 20 to oscillate within the welding groove as the welding torch 20 travels around the tube (if required) to completely fill the groove.

Figure 24 shows the torch 20 positioned in a normally centered axial position. In one embodiment, the axial positioning system 118 is configured to provide the torch 20 with an axial travel of +/- 1 inch. For example, as shown in Figures 23 and 25, the welding torch 20 has been moved by the axial positioning system 118 an axial stroke of +1 inch and an axial stroke of -1 inch, respectively, so that the welding torch 20 is positioned at the correct distance from the tube/ desired/predetermined distance for welding.

Figures 23 and 25 show the torch 20 moved along the axis of the tube (by the axial positioning system 118) to a left and right axial position, respectively. In one embodiment, the axial positioning system 118 is configured to move the torch 20 approximately two inches along the axis of the tube into alignment with the weld joint groove. During the welding procedure, the axial positioning system 118 is configured to oscillate the torch 20 across the weld joint (and, if necessary, within the weld groove to completely fill the groove) at a frequency of up to 4 Hz and an amplitude of up to 0.5".

In one embodiment, the axial positioning system 118 may be a linear actuator. In one embodiment, the axial positioning system 118 may include an axial torch (electric) motor, a lead screw, and a lead nut. In one embodiment, the lead nut is driven along the threads as the lead screw is rotated by the motor. In one embodiment, the motor is configured (eg, mechanically coupled) to rotate the lead screw. In one embodiment, the motor is configured to rotate in a clockwise or counterclockwise direction such that the left or right side of the torch moves substantially parallel to the axial axis A-A of the tube (as shown in Figures 23-25). In one embodiment, the motor is configured to be connected indirectly, eg, through a series of gears, to rotate the lead screw. That is, the motor includes an output shaft, and the motor is operably connected to the lead screw through a gear that engages the output shaft of the motor. In one embodiment, the first gear is connected to the output shaft of the motor, the second gear is connected or attached to the lead screw, and the two gears are coupled to each other via one or more other gears. The motor is connected by gears to the lead screw, which turns when the motor is running. In another embodiment, the motor is configured to be directly connected (ie, without a gear arrangement) to rotate the lead screw. In one embodiment, the lead nut is configured to interlock with a portion of the axial positioning system such that the lead nut is prevented from rotating with the lead screw. That is, since the lead nut is restricted from rotating together with the lead screw, the lead nut is configured to travel/move left and right together with the lead screw.

In one embodiment, the tilt positioning system 120 is configured to tilt the welding torch 20 about the point where the welding wire contacts the tube. In one embodiment, this configuration maintains a constant distance between the point measured by the laser/inspection detector 22 and the point of application of the weld. In one embodiment, such a positioning system is described in detail in International Patent Application No. PCT/US2015/062558, filed on November 24, 2015, which is incorporated by reference in its entirety into this patent application. In Figures 26-28, some components of the positioning system are not shown so that other components can be clearly seen.

In another embodiment, the welding torch 20 is configured to be tilted by the tilt positioning system 120 about a point radially outward from the welding point. This configuration changes the distance between the point measured by the laser/inspection detector 22 and the point of welding application. In one embodiment, the one or more processors 26 are configured to calculate the distance between two points and compensate accordingly.

In one embodiment, tilt positioning system 120 is configured to enable torch 20 to change its tilt angle in the plane of travel to account for changes in welding direction relative to the direction of gravity. In one embodiment, the angle of inclination of the torch 20 can be varied to accommodate gravity. In one embodiment, the tilt angle of the torch 20 can be adjusted to compensate for different orientations due to gravity. In one embodiment, the angular orientation of the welding torch 20 is controlled based on the profile of the interface region. In one embodiment, the tilt angle of the welding torch 20 may be adjusted based on the welding profile data to accommodate and/or compensate for other welding conditions (ie, not just gravity).

Since the torch can be articulated during the welding operation, it can take into account the gravitational force acting on the weld pool as the torch rotates around the stationary tube. Specifically, the angle of the welding torch may be changed by operation of at least one torch motor (ie, tilting the torch motor) based on whether the torch is traveling upwards against gravity or downwards with gravity. One or more motors (eg, a tilt torch motor) may also change the angle of the torch in the plane of rotation based on a particular position within the torch's up or down stroke. It will be appreciated that since the torch may be articulated for some embodiments, it may be better angled to accommodate gravity, and need not be set in a fixed position assuming, for example, that it will travel down by gravity alone. In some embodiments, as discussed above, the present patent application contemplates that welding can be done while the torch is moving up (against gravity) or down (with gravity). Additionally, the torch 20 may be articulated based on different rotational positions (eg, a welding operation performed at 10 degrees from top dead center may ideally have slightly different requirements than a weld performed at 90 degrees from top dead center, which This is due, for example, to the gravitational force applied to the weld pool, and at different locations on the pipe to be welded, the tendency for the weld pool to adhere to the surface of the pipe in different ways.

In one embodiment, the welding torch 20 may be configured with a continuously variable torch tilt angle to compensate or accommodate the continuously changing orientation of the welding torch due to gravity. In one embodiment, the torch 20 may be configured to gradually change the torch tilt angle based on where the torch is located (ie, where the torch is welding along the circumferential direction). In one embodiment, the welding torch 20 may be configured such that the welding torch 20 may include different torch tilt angles for any desired angle of rotation. In one embodiment, the welding torch 20 may be configured such that the welding torch 20 may include different torch tilt angles for each 90°, 30°, 60°, or 120° rotation.

In one embodiment, the tilt positioning motor angularly articulates the torch 20 generally in the plane of rotation. In one embodiment, the angular orientation of the welding torch 20 is controlled based on the position of the welding torch. In one embodiment, the welding torch 20 is configured to pivot along the weld about a plane of rotation.

Figure 27 shows the torch 20 positioned in a normal, non-tilted position. In one embodiment, tilt positioning system 120 is configured to provide torch 20 with an angular tilt of +/- 10°. In one embodiment, tilt positioning system 120 is configured to provide torch 20 with an angular tilt of +/- 5°. For example, as shown in Figures 26 and 28, the welding torch 20 has been moved to a -5° or +5° angle of inclination by the tilt positioning system 120, respectively, so that the welding torch 20 is positioned at the correct/desired/predetermined distance from the tube for welding. In another embodiment, the tilt positioning system 120 is configured to provide the torch 20 with an angular tilt of +/- 7°. In one embodiment, tilt positioning system 120 is configured to provide torch 20 with an angular tilt of less than +/- 5°.

In one embodiment, the arc between the pivot point P and the point of impact of the inspection radiation beam on the interface region remains substantially constant during the welding procedure shown in FIGS. 53 and 54 . That is, the arc angle between the welding position measured by the laser/inspection detector 22 and the welding position welded by the torch is constant. In one embodiment, the one or more processors 26 are aware of the constant arcuate distance between the pivot point P (eg, welding tip) and the inspection point, such that the one or more processors 26 are configured based on the pre-weld profile Inspection data or dynamic inspection data to control the articulation and pivotal movement of the welding torch 20 .

The configuration of the welding torch 20 enabling the welding torch 20 to pivot about the pivot point P allows the angle of the welding torch 20 to be changed while welding without affecting the travel speed of the welding torch 20 . This is especially useful for welding systems with multiple torches, for example. In one embodiment, the torch does not change its angle at the same time, in which case it would be beneficial to change the angle of the torch without any detrimental effect on itself or the other torches.

In one embodiment, tilt positioning system 120 includes a tilt torch motor, rail member 122 and guide rollers 124 . In one embodiment, the rail members 122 are configured to engage with guide rollers 124 to facilitate tilted positioning of the welding torch 20 . In the embodiment shown, the guide rolls 124 may include two upper guide rolls and two lower guide rolls. In one embodiment, the tilt positioning system 120 includes one rail member 122 and its four associated guide rollers 124 positioned on opposite sides of the torch assembly.

In one embodiment, the tilt torch motor is configured (eg, mechanically coupled) to rotate the gear. In one embodiment, the motor is configured to rotate in a clockwise or counterclockwise direction to cause the torch 20 to tilt forward or backward. In one embodiment, the tilt torch motor is configured to be coupled to the rail member 122, such as by gearing. That is, the tilt torch motor includes an output shaft, and the gear is connected to the output shaft of the motor. The tilt torch motor is connected by gears to the rail member 122, which moves when the tilt torch motor operates.

In one embodiment, the rail members 122 are configured to guide the upper and lower guide rollers 124 . In one embodiment, upper and lower guide rollers 124 are biased against rail member 122 such that upper and lower guide rollers 124 are configured to enable torch 20 to change its angle of inclination in the plane of travel.

In one embodiment, the external welding system (with the welding torch 20 ) is configured to receive weld profile data (eg, before, during and afterwards), and is configured to move its outer torch 20 and/or tilt its outer torch 20 to achieve full weld penetration based on the received weld profile data. Thus, weld profile data from the inspection system can be used by external welding systems to enable optimal welding.

In one embodiment, the motor that guides the inspection detector 22 also rotates the torch 20 circumferentially about the plane of rotation to produce a weld along the interface region.

In one embodiment, the torch housing assembly is constructed and arranged to enclose the welding torch 20, radial positioning system 116, axial positioning system 118, and tilt positioning system 120 therein. In one embodiment, the torch housing assembly is configured to protect the components of the torch 20 and various components of its axial, radial, and/or oblique positioning system from welding heat and spatter.

In one embodiment, referring to FIG. 29 , the welding torch 20 in combination with the radial, axial and oblique positioning systems 116 , 118 and 120 constitutes a welding torch module 126 . In one embodiment, each torch module 126 is mounted on the circular rail 112 of the U-shaped channel 110 . In one embodiment, each torch module 126 may include its own travel motor 128 .

In one embodiment, the system 10 includes a carriage configured to carry the torch 20 around the interface region 38 between the tubes 12 , 14 . In one embodiment, the carriage is configured to travel along the track 112 of the rail member 88 . In one embodiment, the carriage includes a plurality of roller members configured to engage the rail members 88 . In one embodiment, the carriage may include one or more drive motors. In one embodiment, the shaft of the drive motor includes a pinion gear mounted thereon. In one embodiment, the pinion gear of the drive motor is configured to mesh with the integral rack and pinion 114 on the rail member 88 . In one embodiment, the carriage may include two drive motors, where each motor may be driven with a different output torque to create a preload effect between the two pinions to remove any backlash from the pinions.

For example, in one embodiment, the torch module 126 includes a carriage frame 134 . In one embodiment, the carriage frame 134 has a generally U-shaped channel configuration. In one embodiment, a portion 136 of the carriage frame 134 includes guide rollers 130 . In one embodiment, the rail members 112 of the rail members 88 are configured to engage with the guide rollers 130 to facilitate positioning of the torch module 126 on the rail members 88 . In the embodiment shown, guide rolls 130 may include upper and lower guide rolls. In one embodiment, travel motor 128 is configured (eg, mechanically coupled) to rotate gear 132 . In one embodiment, the travel motor 128 is configured to rotate in a clockwise or counter-clockwise direction to cause forward or backward movement of the torch module/funny frame. In one embodiment, the travel motor 128 is configured to be coupled to the rail member 112 , such as by gear 132 . That is, the motor includes an output shaft, and the gear 132 is connected to the output shaft of the motor. The motor is connected to the rail member 112 by means of gear 132, and the rail member 112 moves when the motor is running. In one embodiment, the rail members 112 are configured to guide the upper and lower guide rollers 130 . In one embodiment, upper and lower guide rollers 130 are biased against rail member 112 such that upper and lower guide rollers 130 are configured to enable torch module 126 to move along the circumference of rail member 88 .

In one embodiment, each torch module 126 is configured to be independently positioned anywhere around the circumference of the tube and to move at any speed within its capabilities, regardless of the speed of travel of any other torches. In one embodiment, the welding travel speed may be between 5 inches/minute and 55 inches/minute. In one embodiment, the travel speed may be faster than 55 inches per minute during inspection operations or when repositioning the torch between welds.

The external welding system 10 may not be perfectly aligned with the welding joint. This can be due to many reasons. For example, as the tube heats or cools, the welded joint may change shape during the weld pass. Due to process variability, the shape of the groove may change at different locations along the circumference. Height of existing material may vary.

In one embodiment, the one or more processors 26 are configured to detect these conditions and dynamically compensate for these conditions during the welding process to deposit the best possible weld.

In one embodiment, an inspection detector 22 (eg, a laser) may be mounted on each torch module to dynamically measure the joint profile before welding begins and during the welding process. In one embodiment, the inspection detector 22 is mounted such that it measures the weld joint a short distance in front of the welding location of the torch. In one embodiment, inspection detector 22 is configured to measure the width and depth of the weld groove. In one embodiment, inspection detector 22 is also configured to measure the shape of the bottom of the weld groove. In one embodiment, the inspection detector 22 is mounted such that the arc angle between the position of the weld joint measured by the inspection detector 22 and the position of the joint welded by the torch is constant, as shown in FIGS. 53 and 54 .

As the torch oscillates within the welding groove, the arc voltage varies with the distance between the torch tip and the welding groove. In one embodiment, by measuring this arc voltage, the one or more controllers 26 are configured to determine whether the oscillation is centered within the weld groove.

In one embodiment, the inspection camera 182 may be configured to lie in a plane with the weld and a short distance along the circumference from the weld. In one embodiment, inspection camera 182 is configured to be oriented to view the weld point and torch tip relative to the weld groove. In one embodiment, inspection camera 182 may be configured to be co-mounted with inspection detector 22 such that it is aimed at the same point on the outside surface of the tube as inspection detector 22 .

In one embodiment, the external welding system 10 is configured to record all welding parameters for each weld pass performed throughout the welding process. In one embodiment, the external welding system 10 is configured to also record data from sensors not involved in the welding process, such as tube temperature, GPS location, or ambient temperature. In one embodiment, the external welding system 10 is configured to receive instructions from a remote system, which instructions may include, but are not limited to, welding parameters and programs (eg, wire feed speed, welding current, welding voltage, welding travel speed, oscillation distance) , Oscillation Rate), update of control method and report of check go/no go. In one embodiment, such a remote system is described in detail in International Patent Application No. PCT/US2015/062558, filed on November 24, 2015, which is incorporated by reference in its entirety into this patent application.

In one embodiment, the inspection detector 22 is configured to be positioned between the first pipe clamp 16 and the second pipe clamp 18 . In one embodiment, the system 10 may also include an inspection camera 182 . That is, in one embodiment, the system 10 may include both the inspection detector 22 and the inspection camera 182, as shown in FIGS. 53 and 54 . In one embodiment, the inspection detector 22 and/or the inspection camera 182 are configured to be positioned axially (relative to the axis of the pipe) between the first pipe clamp 16 and the second pipe clamp 18 . That is, the first tube clip 16 and the second tube clip 18 are each positioned on axially opposite sides of the inspection detector 22 and/or the inspection camera 182 .

In one embodiment, inspection detector 22 may include inspection lasers, three-dimensional (3D) inspection cameras, inspection ultrasonic sensor systems, inspection capacitive probes, and any other inspection detector, as will be understood by those skilled in the art. Where a laser is used, the type of laser may be a laser displacement sensor. In one embodiment, the laser may be an LK-G5000 series ultra-high-speed/high-precision laser displacement sensor manufactured by Keyence. In one embodiment, the laser may be a smart laser sensor, such as the Smart Laser Sensor SLS-050 manufactured by Meta Vision Systems Inc.

In one embodiment, inspection detector 22 includes a transmitter for emitting a beam of inspection radiation and a receiver for receiving inspection signals from the reflected radiation. In one or more embodiments, inspecting the receiver of the detector includes a sensor that detects reflected radiation and generates a signal based on the reflected radiation. The signals are received by one or more processors 26 . In one embodiment, the signal contains data and information corresponding to the three-dimensional profile of the welded joint between the pipes and/or the interface area between the pipes to be welded. This data and information can be used to detect, for example, the relative heights of adjacent tube surfaces at the area to be welded, the relative spacing between tubes, any non-uniformities in the adjacent surfaces to be welded (eg, at their grooves) .

Additionally, because the inspection detector scans along the entire interface between the tubes and/or the entire welded joint between the tubes, a specific interface profile and/or a specific weld profile can be determined at any specific area of the scan. This information may also be used by one or more processors to control the operation of the welding torch to provide a customized/tuned weld that is tailored specifically to the structural profile of the tube to be welded at its interface region. This information may also be used by one or more processors to control the operation of the grinder 30 to provide a customized/tuned grind tailored specifically to the structural profile adjustment of the welded pipe.

In one embodiment, an inspection detector motor is operably associated with the inspection detector 22 to direct the inspection radiation beam along the interface region 38 between the pipes 12 , 14 to be welded and the weld between the pipes 12 , 14 The joint 36 guides.

In one embodiment, the inspection detector includes a motor that drives the inspection detector along the weld joint. In one embodiment, the torch is configured to attach to the same structure as the inspection detector. In one embodiment, the system 10 includes a motor configured to move/drive both the inspection detector and the welding torch along the welding joint.

In one embodiment, system 10 may include two inspection detectors. In one embodiment, one of the two inspection detectors may be a lead inspection detector configured to guide the welding torch during the welding procedure and also provide pre-welding data. In one embodiment, the other of the two inspection detectors may be a tail inspection detector configured to be behind the welding torch during a welding procedure and to provide post-weld data. In one embodiment, the angle between each inspection detector and the torch may be adjustable.

In one embodiment, inspection cameras 182 and inspection detectors 22 are operably connected to one or more processors 26 . In one embodiment, communication with system 10 (including with inspection detector 22 , with inspection camera 182 , and/or with other electronic modules of welding system 10 ) may be performed wirelessly. In another embodiment, communication with the system 10 (including with the inspection detector 22 , with the inspection camera 182 , and/or with other electronic modules of the welding system 10 ) may be performed using a wired connection. It should be understood that where multiple torches are provided, multiple inspection detectors/lasers may also be provided.

In one embodiment, a computer system and its one or more processors 26 may be located in system 10 . In another embodiment, the computer system and its one or more processors 26 may be located remotely from system 10 . In one embodiment, the one or more processors 26 may include digital processors, analog processors, digital circuits designed to process information, analog circuits designed to process information, state machines, and/or for electronically Other agencies that process information.

It is to be understood that "one or more processors" as disclosed herein may constitute a single processor that is located on the board of the particular system or component in question and locally on the board of the particular system or component in question external and local, or remote from the particular system or component in question. Additionally, connections to one or more processors may be wired or wireless. In addition, "one or more processors" may also refer to multiple processors on-board and locally, multiple processors off-board and locally, multiple processors remotely located, or on-board (and local), off-board (and local), and any combination of remote processors. When referring to an on-board processor, such a processor refers to a processor that is physically carried (ie, physically connected and moved) by a particular system or component. When referring to off-board processors, these refer to processors that are local to the job site and communicate wirelessly with on-board electronics.

In one embodiment, the system 10 does not include an access lever/connection, and may include a steering connection to connect the system 10 to a deployment system (eg, a truck). In one embodiment, the navigation link is not a rigid link. In one embodiment, an off-board processor may also refer to electronics that are attached to the on-board system through a non-rigid navigational connection and that are local to the job site. That is, if a handler moves with a non-rigid manipulation navigation link, it can also be considered an "on-board" handler.

In one embodiment, the one or more processors 26 are also configured to secure the welding system 10 from movement at a position on the tubes 12, 14 that positions the inspection detector 22 relative to the interface region 38 such that The inspection detector 22 is capable of detecting the contour of the interface region 38 between the tubes 12 , 14 . In one embodiment, the one or more processors 26 are also configured to secure the welding system 10 from movement at a location on the tubes 12, 14 that positions the inspection detector 22 relative to the welded joint 36 such that The inspection detector is capable of detecting the weld profile between the tubes 12 , 14 .

The term "motor" as used herein broadly refers to any type of electromechanical motor, such as, by way of example only, electric motors, hydraulic motors, air motors.

In one embodiment, the system 10 may include a feedback system (eg, using an inspection detector 22, one or more processors 26, motors (including axial, tilt, and radial positioning motors for torches; axial , tilt and radial positioning motors; inspection detector/camera motors), first and second fixtures 16 and 18, welding torch 30, as will be described in detail below), the feedback system is configured to sense the first Are the ends of the first and second tubes 12 and 14 properly aligned.

Figure 30 shows a grinder 30 according to an embodiment of the present patent application. As shown in Figure 30, the grinder 30 is positioned to grind the weld start location, and the torch module 126 (with the torch 20 and all its positioning systems) is positioned midway through the weld bead.

In one embodiment, the grinder 30 is configured to grind the weld initiation point of each weld to a smooth profile before the ends of the welds can be mixed. After the weld stop has been blended to the weld start, the weld can be reground to provide a consistent surface height for the next weld. In one embodiment, the grinder 30 may also grind the entire circumference of the weld to smooth the final surface of the weld after all welds are complete.

In one embodiment, referring to Figures 30-33, the grinder module 140 includes a grinder head 30, an axial positioning system 152, a radial positioning system 144, an inspection detector 22 (eg, a 3D scanner), and one or more processes device 26. In one embodiment, the grinding head 30 includes a motor 146 , a gear box 148 and a grinding member/disc 150 . In one embodiment, the positioning systems 144 and 152 include an axial motor 156 , an axial guide 160 , a radial motor 168 , a radial guide 176 and a radial spring 178 . In one embodiment, the grinder module 140 also includes an electronics module 166 and a removable battery 164 . In one embodiment, the electronics module 166 includes one or more processors 26 .

In one embodiment, each of the torch module, grinder module, and inspection module may include a separate electronics module (with one or more processors). In another embodiment, the torch module, grinder module, and inspection module may have a common electronics module (with one or more processors). In one embodiment, each of the torch module and the grinder module may include a separate inspection detector. In another embodiment, the torch module and the grinder module may include a common inspection detector.

In one embodiment, the radial positioning system 144 of the grinder 30 (shown in FIGS. 31 and 32 ) is configured to effect radial movement of the grinder or head 30, and the axial positioning system 152 (shown in FIG. 33 ) shown) is configured to effect axial movement of the grinder 30 . In one embodiment, the grinder 30 may also include a tilt positioning system configured to effect tilt movement of the grinder 30 . In one embodiment, the structure and operation of the grinder's tilt positioning system may be similar to the structure and operation of the welding torch 20 tilt positioning system (described above in this patent application).

In one embodiment, the radial positioning system 144 is configured to move the grinder 30 to any radial distance required for grinding. In one embodiment, the radial movement of the grinder 30 may be spring loaded so that the grinder 30 applies a consistent force to the surface of the tube (of the welded joint). In one embodiment, the radial positioning system 152 is configured to move the grinder 30 away from the surface of the tube when the grinder 30 is not grinding.

In one embodiment, the grinder 30 is mounted for radial movement by the radial positioning system 144 such that the grinding disc 150 is configured to move toward and away from the welding surface of the tube. In one embodiment, the one or more processors 26 are configured to control the one or more grinders 30 to adjust the radial distance of the welded joints between the grinding discs 150 and the tubes 12 , 14 . In one embodiment, the radial positioning system 144 of the grinder 30 is configured to retract the grinder 30 away from the tube to prevent damage when moving from one grinding position to the next. In one embodiment, the grinder 30 can be moved between the grinding configuration and the lifting configuration by the radial positioning system 144 .

In one embodiment, the radial positioning system 144 of the grinder 30 is configured to allow the grinder 30 to be positioned at the correct height for the grinding procedure. In one embodiment, as each grinding procedure is completed, the grinder 30 is moved (by the radial positioning system 144) away from the center of the tube before the next grinding procedure can begin. In one embodiment, the one or more processors 26 are configured to control the one or more motors to move the grinding disc 150 radially away from and toward the weld joint. In one embodiment, the radial positioning system 144 is configured to enable the grinder 30 to move radially to track changes in the weld bead/joint, to adjust the distance of the grinding disc from the workpiece (eg, tube) and as the grinder 30 travels when retracted away from the tube. That is, during each grinding procedure, the radial positioning system 114 is configured to track the bead/joint deviation in order to maintain a constant distance between the grinding disc and the welded joint.

In one embodiment, the radial positioning system 144 may include a linear actuator. In one embodiment, referring to FIGS. 31-33 , the radial positioning system 144 includes a radial (electric) motor 168 , a radial lead screw 170 and a radial lead nut 172 . In one embodiment, the motor 168 is configured (eg, mechanically coupled) to rotate the lead screw 170 . In one embodiment, the motor 168 is configured to rotate in a clockwise or counterclockwise direction to raise or lower the torch 30 substantially parallel to the radial axis R-R of the tube (shown in FIGS. 21 and 22 ). In one embodiment, the motor 168 is configured to be directly connected to rotate the lead screw 170 . In another embodiment, the motor 168 is configured to rotate the lead screw 170 indirectly, eg, through a series of gears or gearboxes. In one embodiment, lead screw 170 includes threads machined on its outer surface and extending along its length. In one embodiment, the lead nut 172 is constructed and arranged to be threaded onto the lead screw 170 and includes complementary threads machined on an inner surface thereof. In one embodiment, lead nut 172 is configured to interlock with a portion of radial spring plate 174 such that rotation of lead nut 172 is prevented along with lead screw 170 . That is, the lead nut 172 is constrained from rotating with the lead screw 170 , and thus the lead nut 172 is configured to travel up and down the lead screw 170 .

When the lead screw 170 is rotated by the motor 168, the lead nut 172 is driven along the threads. In one embodiment, the direction of movement of the lead nut 172 depends on the direction in which the lead screw 170 is rotated by the motor 168 . The radial spring plate 174 is configured to travel/move (up or down) the lead screw 170 with the lead nut 172 when the lead nut 172 is interlocked in the opening of the radial spring plate 174 . The slidable engagement between radial spring plate 174 and guide member 176 also facilitates this (up or down) travel/movement of radial spring plate 174 .

In one embodiment, the spring 178 is configured to push the grinding head 30 away from the radial spring plate 174 against a stop on the end of the radial guide 176 . In one embodiment, stops on the ends of the radial guides 176 are constructed and arranged to engage portions of the grinding head 30 to facilitate radial movement of the grinding head 30 . The radial motor 168 continues to drive the radial spring plate 174 closer to the surfaces of the tubes 12 , 14 as the grinding head 30 makes contact with the weld. This compresses the spring 178 and increases the force of the grinding head 30 against the weld. As the grinding head 30 removes the solder material, the spring 178 continues to push the grinding head 30 against the weld with minimal force reduction.

In one embodiment, the grinder 30 is configured to move axially to align with the welded joint. In one embodiment, the grinder 30 is configured to move axially while grinding to cover the entire width of the weld and produce a smooth surface without gouges.

FIG. 33 shows the axial positioning system 152 of the grinder 30 . In one embodiment, the positioning system 152 includes a linear actuator with a motor 156 . In one embodiment, the grinder 30 is moved axially by rotating a nut built into the axial motor 156 . That is, the actuator is configured with a fixed lead screw 163 . In one embodiment, the lead screw 163 is fixedly attached to the grinder carriage frame (as described in detail below).

In one embodiment, the positioning system 152 includes a housing member 165 that is configured to move linearly (along axis L-L) as its built-in hollow shaft motor 156 rotates the nut. That is, the lead screw 163 is fixed, and the nut is rotated by the motor 156 (ie, built into the housing member 165 ), so that the housing member 165 moves in a straight line (along the axis L-L). In one embodiment, the housing member 165 is fixedly connected to the motor 156 . When the grinder 30 is connected to the housing member 165, the grinder 30 is configured to move linearly with the housing member 165 (along axis L-L).

In one embodiment, the system 10 may include one or more grinders 30, each grinder being configured to perform different operations at different times during the welding procedure. That is, the system 10 may include one type of grinder configured to grind the weld origin. For example, the hard disk 151 as shown in FIG. 34 can be used to grind the welding starting point. System 10 may include another type of grinder that is configured to grind and clean contours after welding is complete. For example, a wire wheel 153 as shown in Figure 35 can be used to grind and clean the profile after welding is complete. In yet another embodiment, the system 10 may include a grinding wheel as shown in FIG. 36 configured to grind the portion of the welded joint.

In one embodiment, at least a portion of the weld joint 36 on which the grinding procedure is performed by the grinder 30 includes the weld start location of the weld joint 36 . In one embodiment, the start of the weld is ground before the torch 20 completes the weld bead. Therefore, the grinding process is performed while the welding torch 20 is performing the welding process. In one embodiment, the grinder 30 is configured to move along the length of the weld. In one embodiment, the grinder 30 is configured to move along the weld while grinding to create a gentle slope at the weld start location.

In one embodiment, the grinder is configured to grind at least one weld start location of the welded joint. In one embodiment, the one or more processors are configured to cause the grinder to grind a circumferential length of between 2 degrees and 20 degrees. In one embodiment, the grinder is configured to grind in a range from the end of the weld (ie, 0 degrees) up to 20 degrees. In one embodiment, it may be between 5 and 10 degrees from the end of the weld.

In another embodiment, at least the portion of the weld joint 36 on which the grinding procedure is performed by the grinder 30 includes the weld end location of the weld joint 36 . In yet another embodiment, at least the portion of the welded joint 36 on which the grinding procedure is performed by the grinder 30 includes the entire circumference of the welded joint 36 . In one embodiment, the welding path of the welding torch 20 generally extends from a welding start position to a welding end (or end) position.

In one embodiment, grinder 30 is configured to grind at least one weld endpoint location of the welded joint. In one embodiment, the one or more processors are configured to cause the grinder to grind a circumferential length of between 2 degrees and 20 degrees. In one embodiment, the grinder 30 is configured to grind in a range from the end of the weld (ie, 0 degrees) up to 20 degrees. In one embodiment, it may be between 5 and 10 degrees from the end of the weld.

In one embodiment, the grinder 30 is configured to grind the overlapping area between the start and end portions of the welded joint.

In one embodiment, the grinder 30 is configured to grind the entire circumference of one of the plurality of layers of solder material (eg, a weld bead layer, including but not Limited to root bead, hot bead, filler and cap bead). In another embodiment, subsequent layers of solder material may be added without grinding the entire circumference of the previous layer of solder material. That is, in one embodiment, the torch is configured to form the first layer of welding material, the grinder 30 is configured to grind the entire circumference of the first layer of welding material, and then the torch is configured to grind the first layer of welding material A second layer of solder material is formed on top of one layer of solder material.

In one embodiment, grinder 30 is configured to move independently of welding torch 20 to grind at least the portion of weld joint 36 . In one embodiment, grinder 30 is configured to grind at least the portion of weld joint 36 while torch 20 forms at least another portion of weld joint 36 .

In one embodiment, grinder 30 is mounted separately from torch 20 .

In one embodiment, the grinder 30 includes an inspection detector 22 (eg, a laser) configured to measure the profile of the weld before the grinding procedure begins. In one embodiment, the inspection detector 22 is also configured to inspect the results of the grinding to verify that the final profile is acceptable.

In one embodiment, the grinder 30 is configured to include an inspection camera 182 mounted to look along the weld joint to observe the contour of the weld groove. In one embodiment, images from inspection cameras 182 may be transmitted to the operator/user for visual inspection. In one embodiment, images from inspection cameras 182 may be processed by one or more processors 26 to determine the contour of the welded joint.

In one embodiment, the location of the grinder 30 is determined based on the profile of the welded joint 36 between the tubes 12 and 14 . In one embodiment, the one or more processors are configured to determine characteristics of the weld profile, and based on the determined characteristics of the weld profile, send a signal to the grinder 30 to move based on the characteristics of the weld profile at a particular location to that specific location.

In one embodiment, one or more processors 26 of system 10 are configured to control one or more grinder motors 156 , 168 to control the position and/or orientation of grinder 30 .

In one embodiment, the grinder 30 is configured to be mounted in a fixed location. If all weld passes start at the same location around the circumference of the weld joint, the grinder 30 is mounted at a single location that is not on the track.

In one embodiment, the grinder 30 and all sensors and motors that are part of the grinder 30 are configured to be powered using a cable connection. In one embodiment, the grinder 30 and all sensors and motors that are part of the grinder 30 are configured to be battery powered to eliminate cable interference issues with the torch. In one embodiment, the grinder 30 and all sensors and motors that are part of the grinder 30 are configured to be controlled using wired communication. In one embodiment, grinder 30 and all sensors and motors operating with grinder 30 are configured to be controlled using wireless communication.

In one embodiment, the grinder 30 is configured to use a circular grinding member or disk 150 that is configured to grind at least the portion of the welded joint 36 . As mentioned above, in one embodiment, the abrasive member may be a hard abrasive disc 151 as shown in FIG. 34 , a wire brush 153 as shown in FIG. 35 , or a grinding wheel 155 as shown in FIG. 36 .

In one embodiment, the grinder module 140 is configured to be mounted on the rail member 88 . In one embodiment, the grinder module 140 is configured to be mounted on the same rail member 88 as the welding module 126 (shown in Figures 18-20).

In one embodiment, the grinder module 140 is configured to move independently of the welding module 126 . In one embodiment, the grinder module 140 is configured to have its own travel capability such that the grinder module 140 can move independently of the welding module 126 . In one embodiment, the orbitally mounted grinder can travel to any point on the circumference of the welded joint. In one embodiment, the one or more processors 26 are configured to prevent collisions between the torch module and the grinder module. In one embodiment, the one or more processors 26 are configured to control the movement of the torch module and the grinder module to move them away from each other on the same rail member.

In one embodiment, the grinder module 140 may be mounted on the circular rail of the U-shaped channel 110 . In one embodiment, the grinder module 140 includes its own travel motor 138 (shown in FIG. 31 ). In one embodiment, the travel motor 138 is configured to rotate/drive the grinder module 140 circumferentially along the weld joint 36 (rotated 360° relative to the tube axis Y-Y in Figure 30). In one embodiment, travel motor 138 is configured to drive grinder module 140 at least 360° relative to tube axis Y-Y to accomplish rotationally continuous grinding.

In one embodiment, the grinder module 140 includes a grinder carriage frame having a generally U-shaped channel configuration. In one embodiment, a portion of the carriage frame may include guide rollers. In one embodiment, the rail members of the rail members 88 are configured to engage with guide rollers to facilitate positioning of the grinder module 140 . In the embodiment shown, the guide rolls may include an upper guide roll and a lower guide roll. In one embodiment, the travel motor 138 is configured (eg, mechanically connected) to rotate the gears. In one embodiment, the travel motor 138 is configured to rotate in a clockwise or counterclockwise direction to cause clockwise or counterclockwise movement of the grinder module/carriage frame. In one embodiment, the travel motor 138 is configured to be coupled to the rail member, eg, through gears. That is, the motor may include an output shaft, and the gear is connected to the output shaft of the motor. The motor is connected by gears to the rail members which move when the motor is running. In one embodiment, the rail member is configured to guide the upper and lower guide rollers. In one embodiment, the upper and lower guide rollers are biased against the rail member such that the upper and lower guide rollers are configured to enable the torch module 140 to move along the circumference of the rail member 88 . In one embodiment, each grinder module 140 is configured to be independently positioned anywhere around the circumference of the tube and move at any speed within its capabilities. In one embodiment, the grinder 30, the grinder module 140, and/or the grinding program may be optional in the system 10.

37-39, the system 10 for welding two tubes 12, 14 further includes an enclosure 200 configured to enclose the welding torch 20 (shown in FIGS. 21-27), the first and the interface region 38 between the second pipe clamps 16 , 18 (shown in FIGS. 21 and 24 ) and the pipes 12 , 14 . In one embodiment, the envelope 200 is also configured as the envelope inspection detector 22 . In one embodiment, the envelope 200 is configured to protect the welding process from wind, dust, debris, and hail.

In one embodiment, the enclosure 200 has a frame 202 that includes a plurality of frame members 204 connected to each other, eg, to form a framework. The framework generally provides the structural integrity and shape of the envelope 200 . In one embodiment, the frame 202 of the enclosure 200 is configured to support the system 10 when the system is not lifted. In one embodiment, the enclosure 200 is constructed and sized to enclose the welding torch 20 (shown in FIGS. 21-27 ), the first and second tube clips 16 , 18 (shown in FIGS. 21 and 24 ) shown) and the interface region 38 between the tubes 12, 14 located entirely therein.

In one embodiment, referring to Figure 39, the enclosure 200 includes a horizontally oriented bottom frame member 204hf and a horizontally oriented top corner frame member 204hrc. Frame members 204hf and 204hrc are connected to each other using vertically oriented corner frame members 204vc. On each side of the enclosure 200 (ie, looking at the front of the enclosure 200 in Figure 38), the frame members 204hf, 204hrc and 204vc are all connected to each other to form a rectangular or square side frame. In one embodiment, angularly oriented reinforcing frame members 204ar may be attached to portions of frame members 204vc and 204hf to further strengthen the side frame of the enclosure 200 .

In one embodiment, the enclosure 200 also includes a rectangular or square top frame formed by four horizontally oriented top corner frame members 204hrc connected to each other. In one embodiment, the top frame of the enclosure 200 is further reinforced by horizontally oriented reinforcing frame members 204hr. Four horizontally oriented reinforcing frame members 204hr are shown in the embodiment shown in FIG. 39 . In one embodiment, the enclosure 200 also includes a top panel 206 (shown in FIG. 37 ) connected to four horizontally oriented top corner frame members 204hrc. In one embodiment, the four horizontally oriented reinforcement frame members 204hr are connected to the four horizontally oriented top corner frame members 204hrc and the top panel 206 after the top panel 206 is connected to the four horizontally oriented top corner frame members 204hrc.

The horizontally oriented top corner frame member 204hrc is connected to two corresponding vertically oriented corner frame members 204vc to form the rectangular/square shaped front and rear frames of the enclosure 200 . In one embodiment, the horizontally oriented frame intermediate members 204ih are constructed and arranged to connect to corresponding vertically oriented corner frame members 204vc to further strengthen the respective front and rear frames of the enclosure 200 . In one embodiment, the angularly oriented reinforcing frame members 204ar are constructed and arranged to connect to corresponding vertically oriented corner frame members 204vc and corresponding horizontally oriented frame members 204ih to further strengthen the corresponding front of the enclosure 200 frame and post frame.

In one embodiment, all frame members 204 (including vertically, horizontally, or angularly oriented frame members) have the same cross-sectional shape. In another embodiment, the frame members 204 may have different shaped cross-sections. In other embodiments, the number, orientation, and positioning of frame members 204 may vary.

In one embodiment, the enclosure 200 includes closure assemblies 2081 , 208r hingedly connected to the frame 202 . In one embodiment, the closure assemblies 208l, 208r are hingedly connected to the horizontally oriented top corner frame members 204hrc of the frame 202. In one embodiment, each closure assembly 208l or 208r is constructed and arranged to provide a top closure portion 210, side closure portions 212, 214, 216, bottom closure portion 218, and front and rear closures of the enclosure 200 Section 220 (only the front closure is shown in the figures, and the rear closure is a mirror image of the front closure).

In one embodiment, the closure assemblies 2081 , 208r are configured to move between a closed position as shown in FIG. 37 and an open position as shown in FIGS. 38 and 39 .

Each closure assembly 2081 or 208r is constructed and arranged to include a frame 224 having a plurality of frame members 226 . The plurality of frame members 226 may include vertically, horizontally, and angularly oriented frame members constructed and arranged to support the top closure portion 210, side closure portions 212, 214, 216, bottom closure portion 218, and front and rear closures Section 220. In one embodiment, the frame members 226 may have the same shape in cross-section. In one embodiment, the frame members 226 may have different shaped cross-sections. In one embodiment, the number, orientation, and positioning of frame members 226 may vary.

In one embodiment, the front closure portions 220 ( 2201 and 220r ) of the closure assemblies 2081 , 208r together form the front closure of the enclosure 200 . Likewise, the rear closure portions of the closure assembly together form the rear closure of the enclosure 200 .

Each front closure portion 220 (2201 and 220r) includes a half or semi-circular opening 222 that is formed when the front closure portions 220 (2201 and 220r) are brought together (ie, when the closure assemblies 2081, 208r are moved to the closed position of Figure 37) Fully open (as shown in Figure 37) to receive the tube therein. Similarly, each rear closure portion includes a half or semi-circular opening that, when the rear closure portions are brought together (ie, when the closure assemblies 2081, 208r are moved to the closed position of Figure 37), form a full opening to receive the tube in it.

In one embodiment, the top of enclosure 220 includes a fixed top portion formed by horizontally oriented top corner frame members 204hrc and top panel 206 and a movable top portion. In one embodiment, the movable top portion includes the top closure portion 210 of the closure assembly 2081 or 208r.

In one embodiment, the top of the enclosure 220 may be constructed and arranged to hold all cables and hoses connected to components of the first and second pipe clamps 16, 18, the rail members 88, the torch module 126, inspection Module (including inspection detector 22 and components configured to move inspection detector 22 on rail member 88 ), grinder module (including grinder 30 and components configured to move inspection detector 22 on rail member 88 ) )and many more.

In one embodiment, the top of the enclosure 200 may include a plurality of lift points 228 . For example, four corner lift points 228 are positioned on and connected to the horizontally oriented top corner frame member 204hrc. In one embodiment, four additional lift points 228c are centrally positioned on the fixed top portion of enclosure 200 (formed by horizontally oriented top corner frame members 204hrc and top panel 206). In one embodiment, each centrally located lift point 228c is connected via connector members 230 to two horizontally oriented reinforcement frame members 204hr.

In one embodiment, the enclosure 200 can be lifted from one location to another by a lift point 228 to provide an easily removable enclosure. In one embodiment, the enclosure 200 may be lifted and moved from one position to another using an overhead crane or similar lifting mechanism and by attaching cables to the lifting points 228 . In one embodiment, the enclosure 200 can be hoisted for placement on or removal from the tube.

As shown in Figures 1 and 2, the top fixed/non-pivoting portions 44 of the first clamp 16 and the second clamp 18 are connected to each other using guide rods 40 (40a, 40b). In one embodiment, a portion of the enclosure 200 is constructed and arranged to connect to the guide rods 40 (40a, 40b). For example, referring to Figures 38 and 39A, a portion 230e of the connector portion 230 is constructed and arranged to extend downward (in the direction of arrow A) to connect to the guide rods 40 (40a, 40b). This configuration is configured to fixedly connect the enclosure 200 to the first clamp 16 and the second clamp 18 .

That is, the frame 202 of the enclosure 200 is configured to be attached to the ends of the two non-pivoting guide rods 40 (40a, 40b). In one embodiment, the first clamp 16 and the second clamp 18 support the enclosure 200 when the first clamp 16 and the second clamp 18 are engaged around the tubes 12 and 14 . The frame 202 of the enclosure 200 is configured to support the first clamp 16 and the second clamp 18 when the first clamp 16 and the second clamp 18 do not surround the tubes 12 and 14 .

In one embodiment, the enclosure 200 may include an access door 232 configured to open without releasing the enclosure 200 from the tubes 12 and 14 . In one embodiment, each access door 232 is provided on the side closure portion 214 of the closure assembly 2081 or 208r. In one embodiment, the door 232 may include a window 234 such that the interior of the enclosure 200 may be viewed from the exterior of the system 10 . In one embodiment, the door 232 is configured to be opened using a handle 289 thereon to allow access for maintenance or inspection. In one embodiment, the enclosure 200 may include guide members at each end, wherein the guide members are configured to align the enclosure 200 with the tube.

In one embodiment, the welding torch 20 is an orbital welding machine. In one embodiment, the orbital welder is configured to mechanically rotate through 360° (or through 180° in a double welding procedure) about the stationary tubes 12 and 14 in a continuous process. In one embodiment, the present patent application provides an orbital welder 20 with an integrated enclosure 200 . In one embodiment, the enclosure 200 includes a fixed internal structure or frame such that the enclosure 200 is configured to be disposed on a surface (eg, a floor or ground) without the tubes 12 , 14 being positioned on the enclosure 200 middle.

In one embodiment, as shown in Figures 55-59, when the enclosure 200 is lowered or raised, the ends of the enclosure 200 may have inverted U-shaped guides 502 to maintain the system in the tubes 12, 14 Center on top. Referring to FIGS. 55-59 , the system of the present patent application also incorporates guides 502 to assist in placing the enclosure 200 on the tubes 12 , 14 . The guides 502 are incorporated into the frame member 204 of the enclosure 200 and taper on the bottom edge such that when the system is lowered onto the tubes 12, 14, the guides 502 tend to push the tubes 12, 14 towards the system center of. Referring to Figure 56, when the tubes 12, 14 are near the center position, the guide 502 transitions from inclined to vertical. Referring to Figure 57, once the tubes 12, 14 are centered, the vertical sides of the guides 502 hold them in place.

Referring to FIGS. 40 and 41 , in one embodiment, the system 10 may include a partial or welding enclosure 300 that is configured to be placed around the welding torch 20 only. In one embodiment, the system 10 may also include a torch module enclosure 300 configured to be placed around the torch module 126 .

In one embodiment, the torch module enclosure 300 may be formed from sheet metal material. In one embodiment, the torch module enclosure 300 may have an opening 302 for the torch 20 . In one embodiment, the opening 302 may be surrounded by a flexible member 304 that is configured to compress and extend based on the depth of the weld. For example, the flexible member 304 may comprise a bellows.

In one embodiment, bellows 304 is constructed and arranged to extend beyond torch 20 when system 10 is not welding. As the torch 20 moves toward the tubes 12, 14, the support 306 of the bellows 304 is configured to come into contact with the tubes 12, 14 and stop moving. As the torch 20 continues to move, the bellows 304 is configured to compress until the torch 20 reaches the correct distance from the tubes 12, 14 for welding. In one embodiment, the support 306 of the bellows 304 may have rollers to prevent it from sliding on the tubes 12 , 14 . In one embodiment, the support 306 of the bellows 304 may be a flexible skirt to close small gaps between the support 306 of the bellows 304 and the tubes 12 , 14 .

In one embodiment, envelopes 200 and 300 may be used simultaneously. In another embodiment, only the encapsulant 200 is used. In yet another embodiment, only the encapsulant 300 is used. In another embodiment, the system may be configured to operate without any integrated enclosures 200 and 300 if welding is performed in a building or if some other form of environmental protection exists.

In one embodiment, the torch module includes a limit switch 192 . In one embodiment, provisions for mounting the trigger 194 to the U-shaped rail channel 88 are already included in the system. This configuration provides a redundant method for ensuring that the welding torch is in a safe position before the rail 88 is opened or closed. 50-52 , the carriage 134 may have a limit switch body 196 mounted thereon, with one or more switches 192 mounted on the limit switch body 196 . The rail 88 has a ring of regularly spaced holes 198 so that one or more triggers 194 can be mounted anywhere on the rail 88 . Trigger 194 is configured to activate one or more limit switches 192 when carriage 134 is in a position to place limit switch body 196 adjacent trigger 194 . In this manner, the trigger 194 is configured to indicate when the carriage 134 is in certain positions, as will be understood by those skilled in the art. Triggers 194 are configured to be used alone or in combination to define positions such as home, top, bottom, side, weld start, weld end, safety, or any other position as may be desired.

In one embodiment, system 10 may be deployed using a deployment system. A small version of the system 10 may be carried by a heavy duty pickup truck such as a wrecker (as shown in Figure 42). A larger version of the system 10 may be carried by a tracked vehicle (as shown in Figure 43). In one embodiment, the system 10 may be installed at a fixed location, such as at a reel base or on an offshore pipe laying vessel. In such an embodiment, the system 10 stays in one place and the conduit moves through it. In another embodiment, the system 10 may be lifted by a small crane (as shown in Figure 44). In yet another embodiment, the system 10 may be lifted by a multi-axis robotic positioner (as shown in Figure 45).

In one embodiment, the system 10 may be configured to detect the position of the tube using visual cameras, ultrasonic distance sensors, laser cameras, or any combination. In one embodiment, the system 10 is configured to allow fast travel speeds when the distance to the pipe is large (greater than one foot) and restrict travel to slow speeds when the distance to the pipe is small (less than one foot). In one embodiment, the sensors may be mounted to enclosures, clamps, rails, lifts, and/or transport vehicles. In one embodiment, a sensing device may be deployed remotely, detecting the location of the system 10 and target points on the pipe, and transmitting the measurements wirelessly or by wire to the deployment system.

In one embodiment, the solder joints/beads can be inspected. In one embodiment, after each pass is completed, an inspection detector or laser 22 for guiding the welding torch 20 may be used to measure the outer profile of the completed weld. In one embodiment, after each weld bead is completed, an inspection camera or 2D camera 182 may be used to inspect the outer contour of the completed weld. In one embodiment, the inspection camera or 2D 182 may be co-mounted with the inspection detector or laser 22 .

In one embodiment, after the final weld pass is completed, the eddy current converter and receiver are configured to inspect or measure the quality of the weld. In one embodiment, the eddy current system is configured to be mounted on any travel module (eg, welding or grinding modules). In one embodiment, the eddy current system is configured to be mounted at a location where inspection detectors or lasers of travel modules (eg, welding or grinding modules) are typically located. In another embodiment, the eddy current system is configured to be mounted adjacent to an inspection detector or laser of a travel module (eg, a welding or grinding module).

In one embodiment, system 10 includes inspection detectors (lasers and/or cameras) for inspecting welds. In another embodiment, the system 10 includes an eddy current system for inspecting welds. In yet another embodiment, the system 10 includes both an eddy current system and an inspection detector (laser and/or camera) for inspecting welds.

A surface crack is usually detectable if it is on the same side where the inspection is being performed, but not if it is on the opposite side of the inspection. For example, external inspection of the tube cannot detect internal defects unless the tube is very thin (eg, less than about 1/8"), or unless the tube is made of a non-ferromagnetic material. Non-ferromagnetic materials include stainless steel (eg , 300 series) and other CRA materials.

In one embodiment, eddy current systems and inspection detectors (lasers and/or cameras) are used together as complementary inspection techniques. For example, in one embodiment, the eddy current system is configured to detect or inspect features of welded joints that are not easily detected or inspected by an inspection detector or laser. For example, inspection detectors (lasers and/or cameras) are configured to inspect the shape of solder joints, while eddy current systems are configured to inspect for solder cracks/defects, including but not limited to copper cracks/defects, burn cracks/defects, misfires (including LCP/IWM misfire or Pore/IWM misfire) cracks/defects, lack of internal fusion (or non-fusion) cracks/defects, clustered porosity cracks/defects, copper/CP cracks/defects, etc.

In one embodiment, after welding is complete, the system 10 is configured to inspect the weld using an ultrasonic device. In one embodiment, after welding is complete, the system 10 is configured to inspect the weld using an x-ray device.

In one embodiment, the two pipe clamps of the system 10 are configured to be able to transfer the pipe alignment load from one pipe to the other through the connection between the pipe clamps. Otherwise, only one fixture may be used to support all equipment (eg, rails and various modules). In one embodiment, the second movable clamp 18 is not required after the previous one or two passes. The alignment of the two tubes 12, 14 does not change and the welded joint is strong enough to support its own weight. In one embodiment, at this point, the system 10 with the two clamps 16, 18 is moved to start the next joint. In one embodiment, welding at existing joints can be accomplished using a simpler system with only one clamp. This one fixture system provides better access to the weld and fewer space constraints for tools operating on the weld. Since this one fixture system applies the final weld bead, the one fixture system includes an inspection tool mounted thereon to inspect the final weld resulting from the final weld pass procedure.

In one embodiment, as described above, the system 10 uses two fixture arrangements at least during the tube holding procedure (including the tube alignment and tube forming procedures) and during the preceding one or two weld passes. Thereafter, the alignment of the two tubes 12, 14 does not change. At this point, only one fixture may be used to complete the welding at the existing joint.

In one embodiment, the system 10 is configured to inspect the formed bead or joint using an inspection detector. That is, the one or more processors are configured to interact with the inspection detector 22 and/or the inspection camera 182 to determine the interface area and/or the contour of the welded joint after the welding procedure to obtain post-weld data. In one embodiment, the one or more processors are configured to perform a grinding procedure (by a grinder) on the formed welded joint based on the post-weld profile data.

In one embodiment, the one or more processors are configured to interact with the inspection detector 22 and/or the inspection camera 182 to determine the interface area and/or the profile of the welded joint following the grinding procedure to obtain post-grinding data. The post-grinding data can be analyzed manually or by one or more processors to ensure that excess weldment on the surface of the weld joint is removed and/or defects are ground away from the weld joint during the grinding procedure. In one embodiment, the one or more processors are configured to cause a re-welding procedure or another welding procedure to be performed on the affected area (after the grinding procedure) based on the post-grinding profile data.

In one embodiment, the one or more processors are configured to control the grinder to grind away weld defects based on the results from the inspection detector. In one embodiment, the one or more processors are then configured to control the torch to re-weld the affected area based on the results from the inspection detector.

In another embodiment, the one or more processors are configured to control the grinder to grind away based on instructions transmitted from the remote system to the one or more processors based on inspection detector results transmitted from the system to the remote system Welding defects. In one embodiment, the one or more processors are configured to control the torch re-welding subject based on instructions transmitted from the remote system to the one or more processors based on inspection detector results transmitted from the system to the remote system affected area.

In one embodiment, the one or more processors are configured to cause another welding operation (before the grinding procedure) to be performed on the interface region between the tubes based on the post-weld profile data.

In one embodiment, the grinder may be a 60V brushless grinder. In one embodiment, the grinder may be a 60V battery operated grinder. In one embodiment, the grinder may be a 120V brushless grinder. In one embodiment, the grinder may be a 120V battery operated grinder. In one embodiment, the battery may be a lithium-ion battery.

In one embodiment, the rail member 88 may be positioned around and in line with the interface region 38 and/or the welded joint 36 between the tubes 12, 14.

In one embodiment, the rail member 88 may be configured to be positioned between the two clamps 16 and 18 . In one embodiment, the welding torch 20 is configured to be mounted on the rail member 88 between the two clamps 16 and 18 such that the welding torch 20 is positioned with the interface area between the tubes 12 , 14 and/or the welding joint 36 on the same straight line.

In one embodiment, the one or more processors are configured to control the grinder to wait a predetermined period of time after the welding process is completed at a certain location and before the grinding process can begin at that location.

In another embodiment, the grinder 30 and the welding torch are positioned on the rail member a sufficient distance from each other to allow cooling of the grinding process produced by the welding torch at that location before the grinding process is performed by the grinder at that location. Solder beads/joints. In one embodiment, the positioning between the torch and the grinder is controlled by one or more processors.

In one embodiment, no additional waiting time (ie, a predetermined period of time) is required beyond the time required for the torch to move out of its current position, so the grinder can move and perform grinding in that position. In one embodiment, the grinding procedure begins 10 seconds after the welding procedure begins.

In one embodiment, the grinder 30 is radially positioned based on a predetermined (grinder to weld) pressure. In one embodiment, one or more processors may be configured to sense pressure. In another embodiment, one or more processors may be configured to determine pressure/force from relative positioning and spring constants of telescoping mill parts/components. In one embodiment, the one or more processors may determine (grinder to weld) force/pressure load based on weld joint inspection. In another embodiment, the mill axial pressure is constant/standard.

In one embodiment, the one or more processors are configured to obtain information from tilt sensors, motor encoders, and/or limit switches. In one embodiment, the one or more processors are configured to, based on this information, determine the location of all travel modules (including torch modules, inspection modules, and grinder modules) on the rail member at any given time.

In one embodiment, the one or more processors are configured to control one or more travel modules (including the torch module, inspection module, and grinder) when the clamp and/or rail members are moved to their respective open positions module) such that the travel module is positioned away from the hinge of the pivot portion and/or clamp and/or rail member.

In one embodiment, the system 10 may include a grinder chip control system. For example, in one embodiment, the grinder debris control system may include a shroud configured to enclose the grinder to contain dust and debris generated during the grinding process. In one embodiment, the shroud can include a vacuum port so that a vacuum system can be used to suck dust and debris out of the shroud. In one embodiment, the grinder chip control system may include a vacuum system. In one embodiment, the vacuum system is configured to be fully contained on the grinder module.

In one embodiment, the torch module of the present patent application may include multiple torches. For example, in one embodiment, a torch module may include two or dual torches configured to deposit two passes simultaneously.

In one embodiment, the grinding procedure may be performed by a grinder positioned within the tube. That is, the grinding procedure can be performed by an internal grinder positioned within the tube, while welding is performed from outside the tube. In one embodiment, the grinder may be supported by a grinder holder positioned within the tube.

Although the present patent application has been described in detail for purposes of illustration, it is to be understood that such detail is for that purpose only and that the patent application is not limited to the disclosed embodiments, but on the contrary, is intended to cover the appended claims Modifications and equivalent arrangements within the spirit and scope of the claim. Additionally, it is to be understood that this patent application contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.

Claims (4)

1. A system for welding two pipes, comprising:

a pipe clamp assembly comprising a first pipe clamp and a second pipe clamp;

the first clamp is configured to engage an outer surface of a first tube to enable the first clamp to be fixed relative to the first tube, and the second clamp is configured to engage an outer surface of a second tube to enable the second clamp to be fixed relative to the second tube;

a welding torch operatively connected to the tube clamp assembly and configured to form a weld joint between the tubes at an interface area between the tubes; and

an enclosure operatively connected to the pipe clamp assembly and configured to enclose the interface area between the first and second pipe clamps, the welding torch, and the pipe;

wherein the enclosure includes a frame, a top wall and a peripheral surrounding side wall extending from the top wall, the top wall and the peripheral surrounding side wall being supported by the frame to define an interior space enclosing the interface area between the first and second tube clamps, the welding torch, and the tube.

2. The system of claim 1, wherein the first conduit clamp comprises a first non-pivoting portion and the second conduit clamp comprises a second non-pivoting portion, and wherein the first non-pivoting portion and the second non-pivoting portion are constructed and arranged to be connected to each other using a guide member.

3. The system of claim 1, wherein a portion of the frame is constructed and arranged to be connected to the guide member.

4. The system of claim 3, wherein the enclosure further comprises closure assemblies hingedly connected to the frame, wherein each closure assembly comprises an access door.

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