Claims:CLAIMS
What is claimed is
1. A system for automated detection, marking and repair of a welding abnormality, the system connected to a welding unit, the welding unit operable to perform primary welding to form a seam, wherein the system comprises:
- a controller communicably coupled to a detection unit, a marking unit and a repair unit;
- the detection unit configured to monitor operational characteristics of the welding unit and transmit the operational characteristics to the controller, wherein the controller is configured to determine positions of welding abnormality based on the operational characteristics of the welding unit;
- the marking unit configured to mark the positions of welding abnormality; and
- the repair unit operable to receive positions of welding abnormality from the controller and perform repair weld thereon.
2. The system of claim 1, wherein the system further comprises a laser scanner operable to centrally-position the repair unit with respect to welding groove.
3. The system of claim 1, wherein the repair unit performs the repair weld based on instructions from the controller.
4. The system of claim 1, wherein the controller employs an abnormality recognition algorithm to determine the positions of welding abnormality based on variance in the operational characteristics of the welding unit above a threshold value.
5. The system of claim 4, wherein the abnormality recognition algorithm is operable to differentiate between a significant and a non-significant welding abnormality based on the variance in the operational characteristics.
6. A method for automated detection, marking and repair of a welding abnormality, the method comprising:
- monitoring, using a detection unit, operational characteristics of a welding unit operable to perform primary welding to form a seam;
- transmitting the operational characteristics of the welding unit to a controller;
- determining, using the controller, positions of welding abnormality based on the operational characteristics of the welding unit;
- marking the positions of welding abnormality using a marking unit communicably coupled to the controller; and
- receiving positions of welding abnormality by a repair unit from the controller to perform repair weld thereon.
7. The method of claim 6, wherein the method further comprises centrally-positioning the repair unit with respect to welding groove by employing a laser scanner.
8. The method of claim 6, wherein the method comprises performing the repair weld by the repair unit based on instructions from the controller.
9. The method of claim 6, wherein the method comprises employing the repair unit to perform the repair weld from an outside of the pipe.
10. The method of claim 6, wherein the method comprises employing an abnormality recognition algorithm to determine the positions of welding abnormality based on variance in the operational characteristics of the welding unit above a threshold value.
, Description:FORM 2

THE PATENTS ACT, 1970
(39 of 1970)
&
THE PATENTS RULES, 2003

COMPLETE SPECIFICATION

1. TITLE OF THE INVENTION
SYSTEM AND METHOD FOR AUTOMATED DETECTION, MARKING AND REPAIR OF WELDING ABNORMALITY

2. APPLICANT(S)
a) Name :WELSPUN CORP LIMITED
b) Nationality :India
c) Address :WELSPUN HOUSE, 5TH FLOOR, KAMALA CITY, SENAPATI BAPAT MARG, LOWER PAREL (W), MUMBAI – 400013, MAHARASHTRA, INDIA

3. PREAMBLE TO DESCRIPTION

COMPLETE SPECIFICATION
The following specification particularly describes the invention and the manner in which it is to be performed.

TECHNICAL FIELD

The present disclosure relates generally to detection, marking and repair of welding abnormalities; and more specifically, to systems for automated detection, marking and repair of welding abnormalities. Moreover, the present disclosure also relates to methods for automated detection, marking and repair of welding abnormalities.
BACKGROUND
Metal pipes are long, hollow tubular structures used for a variety of purposes, primary being for transportation of fluids from one point to another. Generally, one of the most common processes employed for manufacturing of metal pipes involves forming metal strips into a spiral structure, wherein the spiral structure is welded on the edges to obtain a cylindrical structure. Often, the process involving welding of strips to form the pipe structures comprises a primary and a secondary welding. The primary welding is a first weld that is performed on the strips for development of structures and subsequently the secondary welding is performed. However, during the primary welding process, welding abnormalities are often developed which need to be repaired before the secondary welding is performed.
Conventionally, repairing of welding abnormalities requires a person to crawl inside structure with a grinding machine, head light and protective tools. The person visually inspects the welding on circumference of the structure. The person while crawling an entire length of the structure removes abnormality by grinding. The person marks abnormality location of structure for a welder to perform the repair on the abnormalities. Subsequently, the welder enters the structure with a welding machine and protective tools to repair the abnormalities. The welder performs the weld with an approximate 60 pounds weight of welding equipment while crawling inside the structure and performs manual welding at identified locations.
Furthermore, there are several limitations associated with conventional technologies for repairing the welding abnormalities. As there is human intervention involved in repairing, there is a possibility of abnormalities being missed to be identified. Moreover, the repairing of welding abnormalities may involve reduction in welding quality. Therefore, the repair of welding abnormalities depends on skills of the person who identifies the welding abnormalities and the welder performing the repair. Moreover, as the repair involves working inside the pipe there is a safety challenge associated therewith.
Recently, automatic pipe repairing devices have been developed, wherein such devices can be configured with a spiral welded pipe in a production assembly. Such devices include a rail and two symmetric rotating rolls. The rail is used to run an automatic repair welding trolley, and the rolls are configured to receive and rotate the pipe. Based on the movement of the rail and the rolls, a required repair welding seam can be placed for repair welding. However, such devices involve a plurality of moving parts that involve complex componentry, increasing risk of mechanical failure. Also, currently, these processes are carried out after primary welding has finished and hence involving more time consumption.
Therefore, in the light of foregoing discussion, there exists a need to overcome the aforementioned drawbacks associated with repairing of welding abnormalities caused during primary welding.
SUMMARY
The present disclosure seeks to provide a system for automated detection, marking and repair of welding abnormality. The present disclosure also seeks to provide a method for automated detection, marking and repair of welding abnormality. The present disclosure seeks to provide a solution to the existing problem of manual intervention in repairing of welding defects. An aim of the present disclosure is to provide a solution that overcomes at least partially the problems encountered in prior art, and provides a reliable, automatic repair of welding abnormalities without human intervention.
In one aspect, an embodiment of the present disclosure provides a system for automated detection, marking and repair of a welding abnormality, the system connected to a welding unit, the welding unit operable to perform primary welding to form a seam, wherein the system comprises:
- a controller communicably coupled to a detection unit, a marking unit and a repair unit;
- the detection unit configured to monitor operational characteristics of the welding unit and transmit the operational characteristics to the controller, wherein the controller is configured to determine positions of welding abnormality based on the operational characteristics of the welding unit;
- the marking unit configured to mark the positions of welding abnormality; and
- the repair unit operable to receive positions of welding abnormality from the controller and perform repair weld thereon.
In another aspect, an embodiment of the present disclosure provides a method for automated detection, marking and repair of a welding abnormality, the method comprising:
- monitoring, using a detection unit, operational characteristics of a welding unit operable to perform primary welding to form a seam;
- transmitting the operational characteristics of the welding unit to a controller;
- determining, using the controller, positions of welding abnormality based on the operational characteristics of the welding unit;
- marking the positions of welding abnormality using a marking unit communicably coupled to the controller; and
- receiving positions of welding abnormality by a repair unit from the controller to perform repair weld thereon.
Embodiments of the present disclosure substantially eliminate or at least partially address the aforementioned problems in the prior art, and enables an automatic repair of welding defects with a high accuracy and high quality without human intervention.
Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments construed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1 is a block diagram of a system for automated detection, marking and repair of a welding abnormality, in accordance with an embodiment of the present disclosure;
FIGs. 2A and 2B are block diagrams of the system for automated detection, marking and repair of a welding abnormality, in accordance with another embodiment of the present disclosure;
FIG.3 is a flowchart of a method for automated detection, marking and repair of a welding abnormality, in accordance with an embodiment of the present disclosure;
FIGs. 4A, 4B and 4C are environments for implementation of a system for automated detection, marking and repair of a welding abnormality, in accordance with different embodiments of the present disclosure; and
FIG. 5 is an illustration of steps of method for automated detection, marking and repair of a welding abnormality, in accordance with an embodiment of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION OF EMBODIMENTS
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
In one aspect, an embodiment of the present disclosure provides a system for automated detection, marking and repair of a welding abnormality, the system connected to a welding unit, the welding unit operable to perform primary welding to form a seam, wherein the system comprises:
- a controller communicably coupled to a detection unit, a marking unit and a repair unit;
- the detection unit configured to monitor operational characteristics of the welding unit and transmit the operational characteristics to the controller, wherein the controller is configured to determine positions of welding abnormality based on the operational characteristics of the welding unit;
- the marking unit configured to mark the positions of welding abnormality; and
- the repair unit operable to receive positions of welding abnormality from the controller and perform repair weld thereon.
In another aspect, an embodiment of the present disclosure provides a method for automated detection, marking and repair of a welding abnormality, the method comprising:
- monitoring, using a detection unit, operational characteristics of a welding unit operable to perform primary welding to form a seam;
- transmitting the operational characteristics of the welding unit to a controller;
- determining, using the controller, positions of welding abnormality based on the operational characteristics of the welding unit;
- marking the positions of welding abnormality using a marking unit communicably coupled to the controller; and
- receiving positions of welding abnormality by a repair unit from the controller to perform repair weld thereon.
The present disclosure provides system and method for detection, marking and repair of a welding abnormality automatically without human intervention as compared to conventional methods used for repair of welding abnormality. The conventional methods involve human intervention for identification and repair of abnormality whereas the system discussed in present disclosure automatically identifies and repairs the abnormalities. The present disclosure involves continuously monitoring of primary welding to determine operational characteristics and identifying the abnormality based on these operational characteristics. As a result, there is high accuracy in identification of abnormality and high-quality repair of abnormalities by the present disclosure. Moreover, there is no human safety issues involved in the present disclosure for repairing. Beneficially, the present disclosure also involves marking of locations on which the repair is performed thus enabling identification of location of repair for verification. Beneficially, the present disclosure performs the identification and repair of defects while the primary welding is being performed and thereby repair happens in synchronous with the primary welding without the need of stopping of the primary welding for repair. Beneficially, the present disclosure enables in receiving a feedback to enable enhanced repair of the welding abnormalities.
The present disclosure provides the system for automated detection, marking and repair of the welding abnormality. The system is connected to the welding unit. The welding unit is operable to perform primary welding to form the seam. The primary welding performed by the welding unit is typically a root pass welding. It will be appreciated that the root pass welding is performed to enable joining of two sections of a sheet or strip by forming the seam to enable development of structures such as a pipe. Generally, the root pass welding is performed to keep the two sections of the sheet in a given position to form the desired structure. Additionally, the root pass welding is performed from inside of the desired structure. Moreover, after the primary welding is performed subsequent welding(s) is performed to enable formation of a stronger joint between the two sections of the sheet by increasing depth of the weld. Examples of welding performed by the welding unit include but are not limited to Gas Metal Arc Welding, Gas tungsten arc welding, Submerged arc welding, Shielded metal arc welding, Flux-cored arc welding, Electroslag welding and the like. In an embodiment, the welding unit is operable to perform the weld on a spiral pipe or a helical pipe. Optionally, pipe in a spiral form is beneficial as it enables in development of pipes of varying heights and diameters from a single sheet. In an example, from a single sheet of 100 square meters, pipes of different height and diameter may be formed such as pipes having diameter from 0.5 meter to 4 meter and length from 6 meter to 24 meters. In an example, for manufacturing of helical submerged arc welded pipes, steel strip from a coil is fed in a forming mill where it is guided and passed between various rollers and subsequently formed in to a spiral pipe. While being formed, the subsequent edges of the strip are welded by gas metal arc welding process to keep the formed pipe in the shape till the final submerged arc welding is performed. In another embodiment, the welding is performed on metal plates for various structural applications such as for use in ships. Optionally, the root pass welding is performed at high speed. In an example, the root pass welding is performed at a speed of 7 meter /min. However, the continuous root pass welding by the welding unit may have welding abnormalities such as spatter ring, weld discontinuity, cracks, pores and pinholes, uneven weld and the like while welding from inside the pipe. The aforesaid abnormalities need to be fixed before subsequent welding(s) are performed in order to achieve abnormality free welding and to have good quality of weld. The system automatically identifies the location of defect or discontinuity and performs backup welding from outside the pipe. The automated detection, marking and repair of the welding abnormality enables in repairing the abnormality continuously at a speed equal to or more than that of the root pass welding and thus root pass welding may not be stopped for performing the repair. Moreover, the automated repair enables in quick repair and quick development of the pipe for subsequent welding(s) after root pass welding.
In an embodiment, the welding unit is operable to perform the weld on a metal strip that is being spiralized to be formed into a pipe. Specifically, the welding unit welds the spiral at the seams to form a tubular structure to be used as a pipe.
In another embodiment, the welding unit is operable to perform the weld on metal plates to join them together. The welding unit allows metal plates of different and varying thicknesses and sized to be welded together. Such welding on metal plates are welded for application such as ship building, air conditioning systems, propulsion systems and the like.
The system comprises the controller communicably coupled to the detection unit and the repair unit. Throughout the present disclosure, the term "controller" refers to a device comprising suitable circuitry, logic, code, or interfaces configured to receive, process and respond to inputs based on instructions stored in the controller that drive the system. Examples of controller includes, but is not limited to a microcontroller, a microprocessor, a complex instruction set computing (CISC) microprocessor, a reduced instruction set (RISC) microprocessor, a very long instruction word (VLIW) microprocessor, or any other type of processing and controlling circuit. Moreover, the term "controller" may refer to one or more individual controllers, controlling devices and various elements associated with a controlling device that may be shared by other controlling devices. Additionally, the one or more individual controllers, controlling devices and elements are arranged in various architectures for responding to and processing the instructions that drive the system. The detection unit is configured to detect the welding abnormality in the welding performed by the welding unit and transmit information related to the welding abnormality to the controller. The repair unit is configured to perform repair of the welding abnormality based on detection by the detection unit. The detection unit and the repair unit are discussed in detail herein later in the disclosure. The controller is communicably coupled to the detection unit and the repair unit via wired and/or wireless connections that may be carried out via any number of known protocols, including, but not limited to, Internet Protocol (IP), Wireless Access Protocol (WAP), Frame Relay, or Asynchronous Transfer Mode (ATM).
The system comprising the detection unit is configured to monitor operational characteristics of the welding unit and transmit the operational characteristics to the controller. The term "detection unit" refers to a device comprising suitable circuitry, logic, code, or interfaces configured to monitor operational characteristics at certain interval of time such as every 100 milliseconds. Examples of operational characteristics monitored by the detection unit include but are not limited to welding voltage, welding current, wire electrode extension, welding temperature, electrode tip angle, current polarity, filler metal feed rate and arc travel speed. The detection unit is configured to monitor deviation and corresponding time of the operational characteristics. Moreover, the time herein refers to a time of occurrence of the abnormality and stopping time of the defect. The operational characteristics of the welding unit are monitored as deviations beyond a limit may result in an undesirable weld quality and thereby monitoring enables in identifying areas having such undesirable weld quality. Optionally, the detection unit is configured to monitor the operational characteristics based on pre-stored instructions in a memory of the detection unit. More optionally, the detection unit is configured to store the operational characteristics and corresponding time of monitoring in the memory.
Optionally, the detection unit is a sensor or an array of sensors such that each sensor is configured to measure and detect deviations in different operational characteristics. Optionally, the detection unit may comprise an array of detectors such that each detector is configured to detect deviations in different operational characteristics. In an example, the detection unit comprises ammeters, voltmeters and the like. Optionally, the detection unit may employ one or more cameras to monitor the operational characteristics.
Optionally, the detection unit comprises a transmitter module which is operable to transmit the operational characteristics stored in the memory of the detection unit to the controller via the wired and/or wireless connections described above. Optionally, the detection unit is operable to directly transmit the operational characteristics without storing in the memory.
The controller is configured to determine positions of welding abnormality based on the operational characteristics of the welding unit. Specifically, the controller is configured to identify position or location of the defect and length of abnormality based on the operational characteristics. Moreover, the length of abnormality is based on the duration of the abnormality found using the time corresponding to the abnormality and speed associated with the welding. In an example, a starting time of the welding is 10 a.m. and a speed of welding is 7 meter / min. In such a case, if a welding abnormality is detected from 10:05 a.m. to 10:06 a.m. then the position of welding abnormality starts from 35 meters from a start position of the welding and ends at 42 meters from the start position of the welding. Therefore, the welding abnormality exists for 7 meters at a distance of 35 meters from the start position of the welding.
Optionally, the controller comprises a receiver module configured to receive the operational characteristics and their corresponding time from the detection module via the wired and/or wireless connections. Optionally, the operational characteristics and their corresponding time are stored in a memory associated with the controller.
In an embodiment, the controller employs a defect recognition algorithm to determine the positions of welding abnormality based on variance in the operational characteristics of the welding unit above a threshold value. The term "abnormality recognition algorithm" as used herein refers to any collection or set of instructions employing one or more parameters such that the instructions are executable by the controller or other digital systems inside the controller so as to configure the controller to perform a task that is the intent of the controller which is to determine the positions of welding abnormality. Additionally, the defect recognition algorithm is intended to encompass such instructions stored in a storage medium such as RAM, a hard disk, optical disk, or so forth of the controller. Optionally, the abnormality recognition algorithm refers to software application. Such abnormality recognition algorithm is organized in various ways, for example the abnormality recognition algorithm includes software components organized as libraries, Internet-based programs stored on a remote server or so forth, source code, interpretive code, object code, directly executable code, and so forth.
Optionally, the abnormality recognition algorithm comprises instructions to determine the positions of only those welding abnormalities which have variance in the operational characteristics above the threshold value. In an example, a threshold value for welding voltage is 50 Volts with an acceptable variance of 5 volts above or below 50 volts. In such a case, position of welding abnormality is determined for welding abnormality having welding voltage of 58 Volts while position of welding abnormality is not determined for welding abnormality having welding voltage of 48 Volts.
Optionally, a mathematical model is developed initially to analyze the welding abnormality and identify when there is a discontinuity or abnormality in the welding. Moreover, this mathematical model is then converted to the defect recognition algorithm of the controller. Optionally, the mathematical model is then converted to language of a programmable logic controller which is the main controller for continuous tack welding machine at a forming mill. In an example, the controller is a main controller used for continuous tack welding machine at a forming mill. Optionally, data received by the defect recognition algorithm is analyzed and compared with physical welding to correlate with the welding abnormalities. Welds can be cross verified and compared manually to confirm that the logic of identifying abnormalities which can affect final quality of the weld. Optionally, the abnormality recognition algorithm is operable to receive feedbacks which confirm that the abnormality identified by the algorithm is correct and further based on the feedbacks, change parameters employed for determining the positions of welding abnormality.
In an embodiment, the abnormality recognition algorithm is operable to differentiate between a significant and a non-significant welding abnormality based on the variance in the operational characteristics. The term "significant welding abnormality" refers to a welding abnormality having the operational characteristics above the threshold value and thereby which can result in improper or undesirable welds having defects or discontinuity. In an example, a pipe has a diameter of 1066.8 millimeters (mm) and thickness of 15.24 mm and a welding speed of 6 meter per minute having an arc voltage of +/- 1.3 voltage deviation for 1000 millisecond. In such a case, the abnormality recognition algorithm determines the abnormality as significant and thereby needs a repair.
The system further comprises a marking unit communicably coupled to the controller, wherein the marking unit is operable to mark the positions of welding abnormality. Marking unit may also be referred to as marking apparatus. Optionally, the controller is configured to transmit via a transmitter the position of the welding abnormality to the marking unit. The controller is configured to transmit the position of the welding abnormality and length of welding abnormality. Specifically, the controller provides a start position and a stop position of the marking to be made by the marking unit. Optionally, the system comprises a marking unit controller coupled to the marking unit and the controller of the system to enable communication between the marking unit and the controller of the system. In an example, a single head marking system, for example, one from Rea-Jet, is employed.
Optionally, for marking of abnormality or defect, the marking unit is installed beside the root pass welding point. Moreover, location of marking unit is very important in order to have correct location physically marked and not affected by forming machine rollers, grounding brush assembly and heat of welding. Optionally, marking unit may be of any kind capable for marking on steel including but not limited to paint or spray marking unit. As the material to be welded moves continuously and when the abnormality location is detected by controller (via Abnormality Recognition Algorithm), the location is communicated to the marking unit based on speed of strip being passed through. Moreover, based on the distance of marking unit from welding unit and speed of strip being passed through, the controller determines the location of abnormality for marking. Optionally, the marking made by the marking unit enables in identification of location of repair done by the repair unit of the present disclosure. Beneficially, based on the marking the repair performed by the repair welding may be verified to be appropriate by an authorized person.
The system comprising the repair unit is operable to receive positions of welding abnormality from the controller and perform repair weld thereon. Optionally, the system comprises a repair unit controller coupled to the repair unit and the controller of the system to enable communication between the repair unit and the controller of the system. The repair welding system gets the command directly from controller via the detect recognition algorithm. In an embodiment, the repair unit performs the repair weld from an outside of the pipe. The repair unit is developed to automatically carry out the repair weld from outside of the pipe. The controller is configured to transmit via the transmitter, the position of the welding abnormality to the repair unit. The repair weld increases root face condition for the particular area of the pipe having the welding abnormality. In an example, a thickness of repair weld is kept at 1 to 1.5 mm. Optionally based on the repair weld made by the repair unit necessary changes may be made in the root pass welding performed by the welding unit. More optionally, changes are done for operational characteristics like arc voltage, arc current and the like. Optionally, the repair weld is performed in a temperature range of -4 degree Celsius to +50 degree Celsius. Optionally, the controller of the system is communicably coupled to an abnormality detection controller. The abnormality detection controller is communicably coupled to the repair unit controller and the marking unit controller.
In an embodiment, the repair unit performs the repair weld based on instructions from the controller. The controller is configured to transmit instructions regarding the length of welding abnormality. Specifically, the controller provides a start position and a stop position of the repair weld to be performed by the repair unit. In an example, controller provides a start position of the repair welding as 35 meters from the start position of the root pass welding and provides a stop position of the repair welding as 42 meters from the start position of the root pass welding. Therefore, based on the start and stop positions, the repair weld performs the welding only in the desired positions to be welded. Optionally, the abnormality recognition algorithm may be modified to give signal to repair welding power source to start and stop the repair weld on the pipe from outside.
In an embodiment, the system further comprises a laser scanner operable to centrally-position the repair unit with respect to welding groove. A device comprising the laser scanner is integrated to work in coordination with the controller at the speed of the mill and keeps welding torch of the repair unit at the center of the welding groove. The laser scanner detects the groove formed at the edge of strip as two milled edges of the strip come together. The laser scanner detects the groove and aligns welding head of repair unit to the center of groove.
Optionally, the pipe forming process generates a lot of vibrations that cause disturbances in the laser scanner, which can result in non-uniform repair welds. As a result, the system mounting is modified to minimize distance between laser scanner and welding torch with proper protection swivel adjustments to account for different pipe sizes. Optionally, a marking unit is modified to require minimum maintenance and quick replacement of a paint supply. In addition, the marking unit may also include a pneumatically operated paint can with aerosol.
Optionally, the position of welding torch of repair weld is set at an uphill welding angle to have consistent defect free welding. This welding profile is very important as molten metal generated during welding needs to solidify and this positioning helps to balance gravitational and surface tension forces on the liquid metal as it solidifies.
In an embodiment, the system is installed at a forming mill where pipes are being formed and a welding algorithm is developed in the welding power source to carry out the backup root welding at different speed of the forming mill. Typically, the mill speed varies 3.5 meters per minute to 7.5 meters per minute as per command received from abnormality recognition algorithm.
In an embodiment, the present disclosure descries the controller, the detection unit, and the repair unit is a single device. In the present disclosure, the aforesaid single device stays stationary and the strip being formed into the pipe is moved through.
Optionally, to fully automate and repair the abnormality on line at the point of generation, welding machine is part of the system to make the pipes and are designed to operate at the different speeds of the forming mill.
Optionally, the system is capable of producing different sizes and thickness of welded structures (such as pipes and welded metal plates) and the abnormality recognition algorithm is optimized for delay setting, span and overlap on welding with abnormality and to avoid repairing non-significant abnormalities. Various combinations of welding gases may be used to optimize the repair weld quality and consistency.
Optionally, changes are made to the welding process variable to accommodate the repair welding being done from outside, instead of, from the inside of the pipe. By providing back up welding from outside of the pipe and adjusting the welding parameter, in a way that the location of abnormality will be re-melted without having excessive penetration causing burn through. The repair weld made on the outside of the pipe will provide support and prevent excessive penetration.
Moreover, the present description also relates to the method as described above. The various embodiments and variants disclosed above apply mutatis mutandis to the method.
Optionally, the method further comprises centrally-positioning the repair unit with respect to welding groove by employing a laser scanner.
Optionally, the method comprises performing the repair weld by the repair unit based on instructions from the controller.
Optionally, the method comprises employing the repair unit to perform the repair weld from an outside of the pipe.
Optionally, the method comprises employing an abnormality recognition algorithm to determine the positions of welding abnormality based on variance in the operational characteristics of the welding unit above a threshold value.
Optionally, the method comprises differentiating between a significant and a non-significant welding abnormality by the abnormality recognition algorithm based on the variance in the operational characteristics.
Optionally, the method comprises marking the positions of welding abnormality by a marking unit communicably coupled to the controller.
DETAILED DESCRIPTION OF THE DRAWINGS
Referring to FIG. 1, illustrated is a block diagram of a system 100 for automated detection, marking and repair of a welding abnormality, in accordance with an embodiment of the present disclosure. The system 100 is connected to a welding unit 102. The system 100 comprises a controller 104, a detection unit 106 and a repair unit 108. The welding unit 102 is operable to perform primary welding to form a seam. The controller 104 is communicably coupled to the detection unit 106 and the repair unit 108. The detection unit 106 is configured to monitor operational characteristics of the welding unit 102 and transmit the operational characteristics to the controller 104. The controller 104 is configured to determine positions of welding abnormality based on the operational characteristics of the welding unit 102. The repair unit 108 is operable to receive positions of welding abnormality from the controller 104 and perform repair weld thereon.
Referring to FIGs. 2A and 2B, illustrated are block diagrams of the system 100 for automated detection, marking and repair of a welding abnormality, in accordance with another embodiment of the present disclosure. The system 100 further comprises a marking unit 200 communicably coupled to the controller 104. The marking unit 200 is operable to mark the positions of welding abnormality. In FIG. 2B, the marking unit 200 is communicably coupled to the repair unit 108.
Referring to FIG. 3, illustrated is a flowchart of a method 300 for automated detection, marking and repair of a welding abnormality, in accordance with an embodiment of the present disclosure. At a step 302, formation of a product is initiated by a welding unit to perform a primary welding on the product. At a step 304, operational characteristics of the welding unit are monitored by a detection unit. At a step 306, the operational characteristics of the welding unit are transmitted to a controller where the operational characteristics are processed and analyzed. At a step 308, abnormality is identified based on variance in the operational characteristics of the welding unit above a threshold value. At a step 310, if the variance in the operational characteristics is below the threshold value then operational characteristics of the welding unit are again monitored for subsequent positions. At a step 312, if the variance in the operational characteristics is above the threshold value then abnormality is identified and repairing is started. At a step 314, the controller records location of abnormality. At a step 316, the controller measures length of the abnormality. At a step 318, the controller measures length of abnormality till start position of abnormality is reached. At a step 320, if the start position is reached, signal is provided to repair unit. At a step 322, if the start position is reached, signal is provided to marking unit. At a step 324, the repair unit starts repairing of the position of abnormality. At a step 326, laser scanner centrally-positions the repair unit with respect to welding groove. At a step 328, controller gives signal to repair unit till stop position is reached. At a step 330, the repair unit stops repair when stop position is reached. At a step 332, a completion of formation of product is checked. If the product formation is not complete operational characteristics of the welding unit are again monitored for subsequent positions. At a step 334, if the product formation is complete, the primary welding and monitoring of the operational characteristics of the welding unit are stopped.
Referring to FIG. 4A, illustrated is an environment 400A in which a system for automated detection, marking and repair of a welding abnormality is implemented, in accordance with an embodiment of the present disclosure. The environment 400A comprises a controller 402 configured to enable continuous primary welding. The controller 402 is communicably coupled to an abnormality detection controller 404. The abnormality detection controller 404 is communicably coupled to repair unit controller 406 and marking unit controller 408. Strips 410 are continuously fed in a direction 412. The strips 410 are root welded where both edges of strips 410 comes together at continuous root welding point 414 to form a pipe 416. A speed of the strips 410 is similar to a speed of a forming mill (not shown). As shown, the environment 400A comprises a marking unit 420 coupled to the marking unit controller 408. The marking unit 420 is configured to mark positions of welding abnormality. Further, the environment 400A comprises a repair unit 422 coupled to repair unit controller 406. The repair unit 422 is operable to receive positions of welding abnormality from the marking unit controller 408 and perform repair weld thereon. The pipe 416 comprises a weld seam 424. The pipe 416 is repaired by positioning the marking unit 420 outside of the pipe 416. The pipe 416 upon being repaired exists the forming mill in a direction 426.
Referring to FIG. 4B, illustrated is an environment 400B in which a system for automated detection, marking and repair of a welding abnormality is implemented, in accordance with another embodiment of the present disclosure. As shown, in the environment 400B the pipe 416 is marked by positioning the marking unit 420 inside the pipe 416.
Referring to FIG. 4C, illustrated is an environment 400C in which a system for automated detection, marking and repair of a welding abnormality is implemented, in accordance with yet another embodiment of the present disclosure. As shown, in the environment 400C, metal plates 428 are continuously fed to enable continuous primary welding. The marking unit 420 is configured to mark positions of welding abnormality on the metal plates 428 after the primary welding of the metal plates 428. The repair unit 422 is operable to receive positions of welding abnormality from the marking unit controller 408 and perform repair weld on the metal plates 428.
Referring to FIG. 5, illustrated are steps of method 500 for automated detection, marking and repair of a welding abnormality, in accordance with an embodiment of the present disclosure. At a step 502, operational characteristics of a welding unit to perform primary welding are monitored using a detection unit. At a step 504, the operational characteristics of the welding unit are transmitted to a controller. At a step 506, positions of welding abnormality are determined using the controller based on the operational characteristics of the welding unit. At a step 508, positions of welding abnormality are received by a repair unit from the controller to perform repair weld thereon.
The steps 502 to 508 are only illustrative and other alternatives can also be provided where one or more steps are added, one or more steps are removed, or one or more steps are provided in a different sequence without departing from the scope of the claims herein.
Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural.