Patent Application
20220219256
The present disclosure relates generally to orbital welding purge systems. In particular, remotely operable orbital welding purge systems are described.
Orbital welding is used to fusion weld high purity chemical and gas lines. High purity chemical and gas lines may be in the form of pipes or tubes. Orbital welding is a mechanized form of gas tungsten arc welding. For gas tungsten arc welding to produce clean and high quality welds, oxygen must be purged from the weld area.
Purging oxygen from the weld area is accomplished by purging the high purity chemical and gas line with high purity argon. It is critical that the argon flow within the line be controlled to provide a specific pressure of high purity argon at the area of the weld. Too little argon pressure results in a concave weld bead, which typically will not satisfy quality control requirements. Too much argon pressure will result in a convex weld bead, or in extreme cases a hole being blown in the weld.
A welder must precisely adjust the flow of argon to maintain a suitable pressure. Precisely adjusting the pressure of argon gas is accomplished by reading pressure in the high purity chemical and gas line and controlling the flow of argon as needed. Measuring the pressure of the argon is typically accomplished with a differential pressure gauge, such as a Magnehelic® gauge. Controlling the flow of argon is typically accomplished by adjusting needle valves controlling argon flow in supply lines and installing restrictors of varying sizes at the end of the line.
The needle valves are located in “purge manifolds” near a source of argon gas. Often the purge manifolds are located a great horizontal distance away from where the weld is taking place. Further, the purge manifolds may be at a different vertical distance, i.e., elevation, than the location of the weld, such as when the weld area requires scaffolding or mobile elevated work platforms to access.
The purge manifolds and the weld areas being spaced significant horizontal and vertical distances apart makes adjusting the needle valves and measuring the pressure in the line inconvenient and/or impractical for a single welder because he or she must repeatedly go back and forth between the target weld area and the purge manifold. Thus, two workers are often employed for the orbital welding process: one worker operates the welding machine and the other adjusts the flow of argon from the purge manifold according to the weld operator's instructions via telephone. Using two workers is costly and an inefficient use of labor.
It would be desirable to have an orbital welding purge system that did not require two workers to operate efficiently. It would further be desirable to have an orbital welding purge system where a single welder located at the target weld area could control the flow of argon from purge manifolds located away from the target weld area. Enabling the welder to control the flow of argon from remote purge manifolds wirelessly would be ideal. It would further be advantageous if the welder could control the flow of argon from remote purge manifolds using data communication over a network or the World Wide Web from a computing device.
Thus, there exists a need for orbital welding purge systems that improve upon and advance the design of known orbital welding purge systems. Examples of new and useful orbital welding purge systems relevant to the needs existing in the field are discussed below.
The present disclosure is directed to orbital welding purge systems including a source, a supply line, an outlet, a flow control system, and a wireless control system. The source provides a supply of a purge gas. The supply line is in fluid communication with the source. The outlet is disposed on at an end of the supply line downstream of the source. The outlet is configured to direct the purge gas to a target weld area when the outlet is disposed proximate the target weld area. The flow control system is configured to selectively control the flow of the purge gas in the supply line from the source. The wireless control system is configured to control the flow control system. In some examples, the orbital welding purge system includes a differential pressure gauge. In some examples, the orbital welding purge system includes a plurality of additional supply lines.
The disclosed orbital welding purge systems will become better understood through review of the following detailed description in conjunction with the figures. The detailed description and figures provide merely examples of the various inventions described herein. Those skilled in the art will understand that the disclosed examples may be varied, modified, and altered without departing from the scope of the inventions described herein. Many variations are contemplated for different applications and design considerations; however, for the sake of brevity, each and every contemplated variation is not individually described in the following detailed description.
Throughout the following detailed description, examples of various orbital welding purge systems are provided. Related features in the examples may be identical, similar, or dissimilar in different examples. For the sake of brevity, related features will not be redundantly explained in each example. Instead, the use of related feature names will cue the reader that the feature with a related feature name may be similar to the related feature in an example explained previously. Features specific to a given example will be described in that particular example. The reader should understand that a given feature need not be the same or similar to the specific portrayal of a related feature in any given figure or example.
The following definitions apply herein, unless otherwise indicated.
“Substantially” means to be more-or-less conforming to the particular dimension, range, shape, concept, or other aspect modified by the term, such that a feature or component need not conform exactly. For example, a “substantially cylindrical” object means that the object resembles a cylinder, but may have one or more deviations from a true cylinder.
“Comprising,” “including,” and “having” (and conjugations thereof are used interchangeably to mean including but not necessarily limited to, and are open-ended terms not intended to exclude additional elements or method steps not expressly recited.
Terms such as “first”, “second”, and “third” are used to distinguish or identify various members of a group, or the like, and are not intended to denote a serial, chronological, or numerical limitation.
“Coupled” means connected, either permanently or releasably, whether directly or indirectly through intervening components.
“Communicatively coupled” means that an electronic device exchanges information with another electronic device, either wirelessly or with a wire-based connector, whether directly or indirectly through a communication network.
“Controllably coupled” means that an electronic device controls operation of another electronic device.
Orbital Welding Purge Systems
With reference to the figures, orbital welding purge systems will now be described. The orbital welding purge systems discussed herein function to purge oxygen from target weld areas with a purge gas.
The reader will appreciate from the figures and description below that the presently disclosed orbital welding purge systems address many of the shortcomings of conventional orbital welding purge systems. For example, the novel systems below enable a single welder to effectively and efficiently purge oxygen from high purity chemical and gas lines with high purity argon. The systems described below enable a welder to adjust the flow of argon to suitable levels to avoid concave weld beads from too little argon pressure and to avoid convex weld bead or holes in the weld from too much argon pressure.
The novel systems below make adjusting needle valves in a remote purge manifold and measuring the purge gas pressure at the target weld area convenient and practical for a single welder by eliminating the need for the welder to go back and forth between the target weld area and the purge manifold. Importantly, the novel systems discussed herein avoid the need to employ two workers for orbital welding. Unlike conventional systems, the systems described below do not require a worker separate from the worker operating the welding machine to be located at the purge manifold to adjust the flow of argon from the purge manifold according to the weld operator's instructions via telephone. As such, the novel systems discussed in this document are less costly and a more efficient use of labor than conventional orbital welding purge systems.
As will be described in more detail below, the novel systems herein desirably avoid requiring two workers to operate efficiently and enable a single welder to control the flow of argon from purge manifolds located away from the target weld area. The novel systems discussed in this document enable the welder to control the flow of argon from remote purge manifolds wirelessly. Further, in some examples the novel systems enable welders to control the flow of argon from remote purge manifolds using data communication over a network or the World Wide Web from a computing device.
Orbital Welding Purge System
With reference to
Source
As depicted in
The size of the source may be varied as needed for a given application. Source 101 and the other components of system 100 are depicted schematically in the figures and their depictions in the figures have no bearing on their actual size or relative size.
The number of sources in the orbital welding purge system may be selected to meet the needs of a given application. The reader should understand that the number of sources may be different in other examples than is shown in the figures. For instance, some orbital welding purge system examples include additional sources than described in the present example.
Purge Gas
The purge gas serves to remove oxygen from target weld area 106 to enable higher quality orbital welding at target weld area 106. In the present example, the purge gas is composed of argon. However, the purge gas may be composed of any currently known or later developed elements, molecules, or mixtures suitable for purging target weld areas of oxygen.
The purge gas may be any currently known or later developed type of purge gas. The reader will appreciate that a variety of purge gas types exist and could be used in place of argon. In addition to the types of purge gases existing currently, it is contemplated that the orbital welding purge systems described herein could incorporate new types of purge gases developed in the future.
Gas Manifold
The gas manifold may be any currently known or later developed type of gas manifold. The reader will appreciate that a variety of gas manifold types exist and could be used in the orbital welding purge systems discussed in this document. In addition to the types of gas manifolds existing currently, it is contemplated that the orbital welding purge systems described herein could incorporate new types of gas manifolds developed in the future.
Supply Line
The role of supply line 103 is to provide a conduit between source 101 and target weld area 106 to deliver purge gas from source 101 to target weld area 106. The reader can see in
The size of the supply line may be varied as needed for a given application. Supply line 103 and the other components of system 100 are depicted schematically in the figures and their depictions in the figures have no bearing on their actual size or relative size.
The supply line may be any currently known or later developed type of supply line. The reader will appreciate that a variety of supply line types exist and could be used in place of the supply line shown in the figures. In addition to the types of supply lines existing currently, it is contemplated that the orbital welding purge systems described herein could incorporate new types of supply lines developed in the future.
Plurality of Additional Supply Lines
Plurality of additional supply lines 124 serves to supply additional or alternative target weld areas with a supply of purge gas. Each supply line in plurality of additional supply lines 124 is in fluid communication with source 101. In some examples, the additional supply lines may be in fluid communication with an alternative source of purge gas rather than all supply lines being in fluid communication with the same source of purge gas.
The plurality of additional supply lines may be any currently known or later developed type of supply line. The reader will appreciate that a variety of supply line types exist and could be used in place of one or more of the plurality of additional supply lines shown in the figures. In addition to the types of supply lines existing currently, it is contemplated that the orbital welding purge systems described herein could incorporate new types of supply lines developed in the future.
The size of the plurality of additional supply lines may be varied as needed for a given application. The number of additional supply lines in the orbital welding purge system may be selected to meet the needs of a given application. The reader should understand that the number of supply lines may be different in other examples than is shown in the figures. For instance, some orbital welding purge system examples include additional or fewer supply lines than described in the present example.
Outlet
Outlet 104 is configured to direct purge gas to target weld area 106 when outlet 104 is disposed proximate target weld area 106. As depicted in
The outlet may be any currently known or later developed type of fluid outlet. The reader will appreciate that a variety of fluid outlet types exist and could be used in place of the outlet shown in the figures. In addition to the types of fluid outlets existing currently, it is contemplated that the orbital welding purge systems described herein could incorporate new types of fluid outlets developed in the future.
Flow Control System
With reference to
As shown in
With reference to
The role of valve 113 is to selectively control the flow of purge gas through supply line 103. In the present example, valve 113 is a needle valve. However, the valve may be any currently known or later developed type of valve. The reader will appreciate that a variety of valve types exist and could be used in place of the valve shown in the figures. In addition to the types of valves existing currently, it is contemplated that the orbital welding purge systems described herein could incorporate new types of valves developed in the future.
Actuator
Actuator 115 serves to selectively operate valve 113. With reference to
Actuator 115 includes a shaft coupled to a valve stem of valve 113 to enable direct drive actuation of valve 113. However, many coupling configurations are contemplated. In some examples, a custom coupler couples the actuator to the valve. The coupling between the actuator and the valve will typically be splined in some manner to allow the valve stem of the valve to move in and out as it is operated.
The actuator may be any currently known or later developed type of actuator. The reader will appreciate that a variety of actuator types exist and could be used in place of the actuator shown in the figures. In addition to the types of actuators existing currently, it is contemplated that the orbital welding purge systems described herein could incorporate new types of actuators developed in the future.
Orbital Welder
The orbital welder functions to fusion weld high purity chemical and gas lines. The size of the orbital welder may be varied as needed for a given application.
The orbital welder may be any currently known or later developed type of orbital welder. The reader will appreciate that a variety of orbital welder types exist and could be used in the present system. In addition to the types of orbital welders existing currently, it is contemplated that the orbital welding purge systems described herein could incorporate new types of orbital welders developed in the future.
Wireless Control System
The reader can see in
As shown in
The wireless control system may be any currently known or later developed type of wireless control system. The reader will appreciate that a variety of wireless control system types exist and could be used in place of the wireless control system shown in the figures. In addition to the types of wireless control systems existing currently, it is contemplated that the orbital welding purge systems described herein could incorporate new types of wireless control systems developed in the future.
Control Module
The role of control module 116 is to selectively activate actuator 115. The reader can see in
The number of control modules in the orbital welding purge system may be selected to meet the needs of a given application. The reader should understand that the number of control modules may be different in other examples than is shown in the figures. For instance, some orbital welding purge system examples include additional or fewer control modules than described in the present example.
In the present example, control module 116 is a motor control board. However, the control module may be any currently known or later developed type of control module. The reader will appreciate that a variety of control module types exist and could be used in place of the control module shown in the figures. In addition to the types of control modules existing currently, it is contemplated that the orbital welding purge systems described herein could incorporate new types of control modules developed in the future.
Network Data Module
Network data module 181 shown in
Handheld Device
Handheld device 117 functions to communicate the control inputs from user 109 to control module 116 via network data module 181. As depicted in
With reference to
However, the handheld device may be any currently known or later developed type of handheld device. Suitable handheld devices include smartphones, tablet computers, remote controls, or other similar devices. The reader will appreciate that a variety of handheld device types exist and could be used in place of the handheld device shown in the figures. In addition to the types of handheld devices existing currently, it is contemplated that the orbital welding purge systems described herein could incorporate new types of handheld devices developed in the future.
User Interface
As shown in
Clicking a given supply line indicator or a given valve percent open reading provides the user with an opportunity to change the position of the valve. That is, the user can send a command to increase or decrease the percent the valve is open. The percent open command can range between 100% open allowing maximum flow of purge gas or 100% close stopping the flow of purge gas.
The user interface may be any currently known or later developed type or style of user interface. The reader will appreciate that a variety of user interface types exist and could be used in place of the user interface shown in the figures. In addition to the types of user interfaces existing currently, it is contemplated that the orbital welding purge systems described herein could incorporate new types of user interfaces developed in the future.
Wireless Network Protocol
In the present example, wireless network protocol 120 uses the WiFi standard to communicate data between computing devices. However, the wireless network protocol may be any currently known or later developed type of wireless network protocol. The reader will appreciate that a variety of wireless network protocol types exist and could be used in the systems described herein. In addition to the types of wireless network protocols existing currently, it is contemplated that the orbital welding purge systems described herein could incorporate new types of wireless network protocols developed in the future.
Differential Pressure Gauge
Differential pressure gauge 111 shown in
With reference to
Turning attention to
A distinction between orbital welding purge system 200 and orbital welding purge system 100 is that handheld device 217 is configured to communicate with control module 216 via a frequency hopping spread spectrum radio transmission 290 in addition to a wireless network data protocol 220 like WiFi. In the present example, the frequency hopping spread spectrum radio transmission 290 utilizes a Bluetooth™ protocol, but any form of frequency hopping spread spectrum radio transmission may be used.
As shown in
Flow control system 207 presents another distinction between systems 100 and 200. In flow control system 207, actuator 215 is a servo motor rather than a stepper motor like actuator 115 in flow control system 107.
The disclosure above encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in a particular form, the specific embodiments disclosed and illustrated above are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed above and inherent to those skilled in the art pertaining to such inventions. Where the disclosure or subsequently filed claims recite “a” element, “a first” element, or any such equivalent term, the disclosure or claims should be understood to incorporate one or more such elements, neither requiring nor excluding two or more such elements.
Applicant(s) reserves the right to submit claims directed to combinations and subcombinations of the disclosed inventions that are believed to be novel and non-obvious. Inventions embodied in other combinations and subcombinations of features, functions, elements and/or properties may be claimed through amendment of those claims or presentation of new claims in the present application or in a related application. Such amended or new claims, whether they are directed to the same invention or a different invention and whether they are different, broader, narrower or equal in scope to the original claims, are to be considered within the subject matter of the inventions described herein.
