CN115229427A

CN115229427A - System and method for welding pipe segments of a pipeline

Info

Publication number: CN115229427A
Application number: CN202210902303.7A
Authority: CN
Inventors: 尚卡尔·拉贾戈帕兰; 西达尔特·马利克; 布莱恩·L·柯克
Original assignee: CRC Evans Pipeline International Inc
Current assignee: CRC Evans Pipeline International Inc
Priority date: 2017-06-23
Filing date: 2017-07-18
Publication date: 2022-10-25
Also published as: ZA201800734B; WO2018236407A1; EP3641974A1; ZA201903996B; MX2018002790A; EP3641974A4; RU2750760C2; RU2018120317A3; CA2995952A1; CN109429490A; RU2018120317A; AU2017314295A1; BR112018006177A2

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 weld joint between the tubes at an interface area between the tubes. The inspection detector is configured to emit an inspection radiation beam. The motor is operably associated with the inspection detector to direct the inspection radiation beam along the weld joint between the pipes. The one or more processors are operatively associated with the inspection detector to determine a profile of the weld joint between the pipes. The grinder is configured to grind at least a portion of the weld joint between the tubes based on the profile of the weld joint between the tubes.

Description

System and method for welding pipe segments of a pipeline

The present application is a divisional application of a patent application (international application date 2017, 7/18, application number 201780003163.7, entitled "system and method for welding pipe sections of a pipeline").

Technical Field

The present patent application relates to a system and method for welding pipe sections of a pipe or pipeline.

Background

A piping system may include a long length of pipe sections or pipe segments (e.g., miles of pipe segments) comprising steel, stainless steel, or other types of metals for transporting fluids such as water, oil, and natural gas between two locations (e.g., from a source, which may be land-based or water, to a suitable storage location). Construction of piping systems typically involves joining together pipe sections of appropriate diameter and length dimensions via welded joints, for example to provide a fluid-tight seal for the joined pipe sections.

During the formation of a weld joint between two pipes or pipe segments (e.g., two pipe segments having the same or similar cross-sectional dimensions), the end of one pipe segment or pipe segment is in close proximity or contact with the end of the other pipe segment or pipe segment. The pipe sections are held relative to each other and a weld joint is formed to join the two ends of the pipe sections using a suitable welding process. After the weld is complete and cleaned, the weld can be inspected.

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

Disclosure of 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 collet is configured to engage an outer surface of the first tube to enable the first collet to be fixed relative to the first tube. The second collet is configured to engage an outer surface of the second tube to enable the second collet to be fixed relative to the second tube. The welding torch is configured to form a weld joint between the tubes at an interface area between the tubes. The inspection detector is configured to emit an inspection radiation beam. A motor is operatively associated with the inspection detector to direct an inspection radiation beam along the weld joint between the pipes. The one or more processors are operatively associated with the inspection detector to determine a profile of the weld joint between the pipes. The grinder is configured to grind at least a portion of a weld joint between the tubes based on a profile of the weld joint between the tubes.

Another aspect of the present patent application provides a system for welding two pipes. The system includes a tube clamp assembly, a welding torch, and an enclosure. The pipe clamp assembly comprises a first pipe clamp and a second pipe clamp. The first clamp is configured to engage an outer surface of the first tube to enable the first clamp to be fixed relative to the first tube. The second collet is configured to engage an outer surface of the second tube to enable the second collet to be fixed relative to the second tube. The torch is operatively connected to the tube clamp assembly and is configured to form a weld joint between the tubes at an interface area between the tubes. An enclosure is operatively connected to the pipe clamp assembly and is configured to enclose an interface area between the welding torch and the pipe.

Another aspect of the present patent application provides a system for welding two pipes. The system comprises: a first clamp configured to engage an outer surface of the first tube to enable the first clamp to be fixed relative to the first tube; a second collet configured to engage an outer surface of the second tube to enable the second collet to be fixed relative to the second tube; a welding torch configured to form a weld joint between the tubes at an interface region between the tubes; and an inspection detector configured to emit an inspection radiation beam.

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

Drawings

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

FIG. 2 illustrates another perspective view of the system of FIG. 1, wherein the torch and torch mounting system are not shown for clarity;

figure 3 shows a perspective view of one of two pipe clamps of a 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;

figures 5 and 6 show partial cross-sectional views of the pipe clamp of figure 3 with the actuator and clamp slide in their retracted positions in figure 5 and the actuator and clamp slide in their extended positions in figure 6;

figures 7 and 8 show 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 figure 7 and in a locked position in figure 8;

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

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

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

figures 14 and 15 show partial cross-sectional views of the pipe clamp of figure 12 with the actuator and clamp slide in their retracted positions in figure 14 and the actuator and clamp slide in their extended positions in figure 15;

figures 16 and 17 illustrate partial cross-sectional views of the pipe clamp of figure 12 showing an interlock mechanism between the clamp blocks according to one embodiment of the present patent application;

FIGS. 18 and 19 illustrate the torch mounting system in its closed position in FIG. 18 and in its open position in FIG. 19;

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

FIG. 21 illustrates a welding torch in a welding position according to an embodiment of the present patent application;

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

FIG. 23 shows a welding torch in a left-most axial position according to an embodiment of the present patent application;

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

FIG. 25 shows a welding torch in a right-most axial position according to an embodiment of the present patent application;

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

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

figure 28 shows the welding torch in a right-leaning position according to an embodiment of the present patent application;

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

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

FIG. 31 shows a perspective view of a system according to an embodiment of the present patent application showing the radial and axial positioning systems of the grinding mill;

fig. 32 shows a perspective view of a system according to an embodiment of the present patent application, showing a radial positioning system of a grinding mill.

FIG. 33 shows a perspective view of a system according to an embodiment of the present patent application showing an axial positioning system of a grinding mill;

figures 34, 35 and 36 show different grinding media that may be used in a grinding mill according to embodiments of the present patent application;

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

FIG. 38 shows a perspective view of an enclosure with walls at least partially open according to an embodiment of the present patent application;

FIG. 39 shows a perspective view of an enclosure with walls at least partially open, with some components removed to more clearly show the frame of the enclosure;

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

figures 40 and 41 illustrate perspective and partial cross-sectional views of a welding enclosure configured to enclose a welding torch and a welding torch module, according to an embodiment of the present patent application;

42-45 illustrate various deployment systems for deploying a system according to embodiments of the present patent application;

FIG. 46 shows a prior art system for aligning pipe ends;

FIG. 47 illustrates a system for aligning tube angles according to an embodiment of the present patent application;

figures 48 and 49 illustrate an angular misalignment between pipe ends (at a weld joint) before and after use of a system for aligning pipe corners, according to an embodiment of the present patent application;

FIG. 50 illustrates a switch trigger mounted on a rail channel according to an embodiment of the present patent application;

fig. 51 and 52 illustrate a switch trigger mounted on a rail channel and a corresponding limit switch mounted on a carriage according to an embodiment of the present patent application, where fig. 52 illustrates the limit switch engaged with the switch trigger and fig. 51 illustrates the limit switch not engaged with the switch trigger;

fig. 53 and 54 illustrate the system of the present patent application in which the inspection camera is mounted in conjunction 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, and fig. 53 and 54 further illustrate that the arc angle between the joint location measured by the inspection detector and the joint location welded by the welding torch is constant; and

fig. 55-59 show guides of enclosures according to embodiments of the present patent application that keep the system centered over the tube when the enclosure is lowered or raised.

Detailed Description

Fig. 1 and 2 show a system 10 for welding two

pipes

12 and 14. The system 10 includes a first tube clamp 16, a second tube clamp 18, and a welding torch 20 (shown in figures 21-27). In one embodiment, as shown in fig. 30-33, the system 10 further includes an inspection detector 22, a motor 24, one or more processors 26, and a grinder 30.

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

In one embodiment, the welding torch 20 is configured to form a weld joint 36 (fig. 21 and 24) between the tubes at an interface region 38 (fig. 21 and 24) between the

tubes

12 and 14. In one embodiment, the inspection detector 22 is configured to emit an inspection radiation beam. In one embodiment, a motor 24 is operatively associated with the inspection detector 22 to direct an inspection radiation beam along the weld joint 36 between the

pipes

12 and 14. One or more processors 26 are operatively associated with the inspection detector 22 to determine the profile of the weld joint 36 between the

pipes

12 and 14. The grinder 30 is configured to grind at least a portion of the weld joint 36 between the

tubes

12 and 14 based on the profile of the weld joint 36 between the

tubes

12 and 14.

The term "profile" as used herein is a generic term used to refer to physical properties of a welded joint between pipes. The term "profile data" refers to data corresponding to a profile, which may be obtained from a weld joint. Such data may be obtained, for example, by scanning the weld joint with an inspection detector (such as a laser). The contour data may contain many types of information about the contour, such different types of information being referred to herein as "characteristics". In one embodiment, the physical properties of the weld joint between the pipes 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 portions.

In one embodiment, the first tube 12 and the second tube 14 are made of a metallic material. In one embodiment, the first and

second tubes

12, 14 are made of a carbon steel material. In one embodiment, the first tube 12 and the second tube 14 are made of a steel alloy 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 made (e.g., completely or partially) of a Corrosion Resistant Alloy (CRA) material. In one embodiment, the CRA material may include an iron-based alloy, such as various grades of stainless steel or nickel-based alloys (i.e., commonly known under the trade name Inconel). In one embodiment, first tube 12 and second tube 14 may be made from American Petroleum institute Specification (API) 5L grade X52 (i.e., 52000PSI minimum yield strength and 66000PSI minimum tensile strength) materials. In one embodiment, the first tube 12 and the second tube 14 may be made from API 5L grade X60 (i.e., 60000PSI minimum yield strength and 75000PSI minimum tensile strength) materials.

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 a 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 section may also be referred to as the outer diameter of the pipe section. 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

pipes

12 and 14 from the outside of the

pipes

12, 14. In one embodiment, the external welding system may be configured to provide a shielding gas outside of the

pipes

12, 14 to be welded (e.g., at the joint).

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 electrode wire into a welding area/zone. For example, a wire feeder and spool 187 are shown in fig. 30. Consumable wire electrode is provided by a source (e.g., a wire spool or spool) through a wire feed system. In one embodiment, the welding torch 20 is constructed and arranged to be connected to a power source (e.g., a constant voltage power source). In one embodiment, an arc is formed between the consumable electrode wire and the

tubes

12, 14, which heats the welding wire and the

tubes

12, 14, causing them to melt and bond. In one embodiment, a shielding gas is fed through the welding torch 20 along with the consumable wire electrode, which shields the welding process from contaminants in the air. In one embodiment, the shielding gas is fed to the welding area/zone through a torch nozzle, which may comprise a gas cup. In one embodiment, the electrodes may extend beyond the end of the gas cup. In one embodiment, the shielding gas stored in the system 10 is directed to the wire feed assembly through a hose/shielding gas line for distribution to the welding 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 near the region where the weld material is to be deposited. If such a bevel is provided, the interface region comprises at least a portion of the bevels of the two pipes to be welded or alternatively the entire bevel. In one embodiment, if a groove is provided, the interface region includes the entire groove surface and also extends beyond the groove 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 a region of the

tubes

12, 14 adjacent where the weld is to be made.

In one embodiment, the ends of the

tubes

12 and 14 are joined together to form a weld groove therebetween. In one embodiment, the weld groove may have a V-shaped cross-sectional configuration, a U-shaped cross-sectional configuration, or other shaped cross-sectional configuration, as will be understood by those skilled in the art. In one embodiment, the ends of the

tubes

12 and 14 may include a beveled surface. 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 along the circumferential ends with the

end connector tubes

12 and 14. In one embodiment, the

tubes

12 and 14 are welded together at their beveled ends.

In one embodiment, the weld joint 36 may include multiple layers of weld material disposed on top of each other in a radially outward direction. In one embodiment, the multiple layers of solder material may be referred to as solder layers. In one embodiment, different beads or layers may be formed sequentially from the outside of the

tubes

12 and 14 by the external welding system 10. The solder layer may be interchangeably referred to herein as a via layer. In one embodiment, the weld bead (e.g., root bead, hot bead, fill bead, cap bead) may be a single advance of the welding tool or welding system 10 along the weld joint 36. In one embodiment, a bead or layer of weld is formed as a result of each weld pass.

The term "collet" as used herein may refer to a clamp structure for fixedly securing to a surface of a tube (e.g., the

outer surfaces

32, 34 of the

tubes

12, 14, respectively). For example, the clamp may include one or more clamp slides 52 or other support structures configured to fixedly engage a surface of the tube (e.g., the respective

outer surfaces

32, 34 of the tubes 12, 14) to prevent movement thereof.

In one embodiment, the pipe clamp may be a toggle clamp of the type whose construction and operation is shown in fig. 3-11 and described with respect to fig. 3-11. In another embodiment, the pipe clamp can be a tapered clamp, the construction and operation of which is shown in fig. 12-17 and described with respect to fig. 12-17.

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

In one embodiment, clamps 16 and 18 of external welding system 10 may be referred to individually or together as a braking system of external welding system 10, which secures external welding system 10 in a desired position on

pipes

12, 14. In one embodiment, clamps 16, 18 are radially extending clamps that engage the outer surface of

tubes

12 and 14, respectively, to secure external welding system 10 against movement.

In one embodiment, each of the first and

second clamps

16 and 18 includes a non-pivoting (or fixed)

portion

44, 44a or 44b and two pivoting or

movable portions

46, 46a or 46b 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 fig. 1 and 2, the top fixed/non-pivoting portions 44 of the first and

second clamps

16, 18 may each include a lift point 287. In one embodiment, the first gripper 16 and the second gripper 18 may each be lifted from one position to another by a lifting point 287 to provide an easily removable gripper. In one embodiment, the first and

second clamps

16, 18 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 287. In one embodiment, the first clamp 16 and the second clamp 18 may each be hoisted to be placed on or removed from the pipe.

In one embodiment, the two pivoting or movable portions of the clamp are configured to allow placement of the clamp on the respective tube. That is, the two pivoting or

movable portions

46 and 48 are configured to be hinged (e.g., about the pivot pin 68) such that the pivoting or

movable portions

46 and 48 swing open to allow the clips to be placed on and removed from the respective tubes. In one embodiment, the position of each pivoting or

movable portion

46 and 48 of the clamp is controlled using a

linear actuator

50, 50a, 50b, 50c or 50 d. For example, as shown in fig. 3 and 4, an actuator 50a is used to control the position of the pivoting or movable portion 46 of the clamp, and an 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 electrical actuator, or any other actuator, as will be appreciated 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 a guide member or guide rod 40. In one embodiment, as shown in fig. 1 and 2, the first clamp 16 and the second clamp 18 are coupled to each other using four guide rods 40 a-d.

Two of the four

guide rods

40, 40a and 40b, are configured to connect the

non-pivotable portions

44a and 44b of the first and

second clamps

16 and 18 to each other. In one embodiment, the two

non-pivotable guide rods

44, 44a or 44b are also configured to support a rail member 88 (as shown in fig. 18 and 19 and described with respect to fig. 18 and 19) that is configured to support a torch module 126 (including the torch 20), a grinder module (including the grinder 30), and an inspection module thereon (including the inspection detector 22 and/or the inspection camera 182).

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 portion

46b and 48b of the second clamp 18. In one embodiment, the guide rods 40c are 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 rods 40d are configured to connect the pivotable portion 48a of the first clamp 16 with the corresponding pivotable portion 48b of the second clamp 18.

Fig. 3 shows the two bottom

pivotable portions

46 and 48 of the clamp in the closed (and locked) position, while fig. 4 shows the two bottom

pivotable portions

46 and 48 of the clamp in the swung 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 pipe to be positioned below the non-pivotable portion 44. When the pipe is in place, the two bottom

pivotable portions

46 and 48 of the clamp can be swung into a locked position.

In one embodiment, the first procedure of welding of the tubes (i.e., welding two tubes together) is a holding procedure of the tubes. 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 process and the tube alignment process 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 performing an alignment procedure for the tube, and vice versa.

In one embodiment, each of the tube clamps 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 given the same shape. This can be accomplished by using the tube clamps 16, 18 for the

respective tubes

12, 14. In one embodiment, as will be explained in detail below with respect to fig. 3-17, each of the pipe clamps 16, 18 includes a series of mechanically coupled gripper/clamp slides 52 that are constructed and arranged to move radially inward toward the corresponding

pipe

12, 14. The mechanical connections connecting adjacent gripper/gripper slides 52 are constructed and arranged to ensure that all gripper/gripper slides 52 are always of 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 (i.e., the two

tubes

12, 14 contacting each other) to a small gap. In one embodiment, the small gap is no more than 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 weld joint 36 during welding.

In one embodiment, the tube alignment procedure may further include a tube centering 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 sliders 52 are coaxial.

During the tube face alignment procedure, in one embodiment, the first and second tube clamps 16 and 18 are configured to be movable relative to the other of the first and second tube clamps 16 and 18 to control the axial gap between the

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 sliders 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 the

clamps

16 and 18 is controlled by two actuators 42 (shown in fig. 1 and 2). One 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 electrical actuator, or any other actuator, as will be appreciated by those skilled in the art.

In one embodiment, one of the first and second tube clamps 16, 18 is configured to move relative to the other of the first and second tube clamps 16, 18 to create an axial compressive force between the

tubes

12, 14.

In one embodiment, the tube corners of the

tubes

12, 14 may be aligned relative to each other at the weld joint by lifting the weld joint using an external crane 190. For example, in one embodiment, the first pipe clamp 16 and the second pipe clamp 18 are lifted from one weld joint to the next by an external crane 190. Since the external crane 190 is configured to always remain connected to the first pipe clamp 16 and the second pipe clamp 18, a net load can be applied to the

pipes

12 and 14 using the external crane 190 to change their relative angles at the weld joint.

Prior art methods for aligning pipe ends typically require that a new pipe 186 be held by a sidearm pipelayer 188 or other lifting equipment for the entire duration of the start of the root pass weld plus the second (hot) pass weld. When each tube is welded, the tube support 184 is placed near the free end. The weight of the tubes causes them to sag between the tube supports 184. This sagging forces the free end of the tube to tilt upwards. For example, FIG. 46 illustrates tube deflection between tubes using this prior art method. In order to have a consistent weld joint profile, the pipe ends must be aligned in the vertical, horizontal and axial directions as well as in the pitch and yaw angles. In prior art methods, to align the unwelded pipe 186 with a previously welded pipe, the unwelded pipe 186 is held in place using a side arm pipelayer 188 to align the two pipe ends in the proper position and angle.

Fig. 47 illustrates a system of the present patent application configured to align tube angles of tubes relative to each other by lifting a weld joint with an external crane 190. The system of the present patent application allows the side arm 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 pass (e.g., the root pass) to complete 100%. In some embodiments, the side arm boom hoist 188 may be moved before the first weld pass begins. Referring to fig. 47-49, the method of the present application begins by placing the tube support 184 near the middle of each tube segment rather than near one end. This allows the ends of two adjacent tubes to sag a similar distance and angle. Once the system of the present 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 weld joint. As will be appreciated by those skilled in the art, the lifting direction need not be in a perfectly vertical direction, but may be any angle required to improve the alignment of two pipe ends. This alignment method therefore allows a small gap between the two pipes for the first (root) pass. That is, where the external crane 190 is able to control the angular alignment of the two

pipes

12, 14, the two

pipes

12, 14 do not need to be in contact to ensure proper angular alignment. This makes it possible to control the relative axial position of the two

tubes

12, 14 using an axial actuator between the two clamps, so that there is a small gap at the interface between the

tubes

12, 14. As will be appreciated by those skilled in the art, by appropriately adjusting the crane 190, the gap at the interface between the two

pipes

12, 14 can be kept consistent to within a small tolerance (e.g., less than 10%) at all points along the interface.

One of the reasons that the

tubes

12, 14 and sliding

clamps

16, 18 can be preloaded together is that they can resist bending forces that would normally be used to create a gap on one side of the weld joint. These bending forces may be controlled by adjusting the vertical load from an external crane 190 configured to lift the enclosure 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 weld joint may be reduced and possibly eliminated.

Fig. 48 and 49 show a comparison of 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 weld joint.

Referring to fig. 5 and 6, in one embodiment, each

clamp

16 or 18 includes a plurality of clamp slides 52 configured to clamp/engage the

respective tube

12, 14. In one embodiment, the clamp slide 52 may have different heights for different sized tubes, and may be fine-tuned, for example, with shims or any other adjustment means. In one embodiment, the size (i.e., outer diameter) of each tube has a corresponding clamp slide size. In one embodiment, the clamp slide 52 is 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 exterior/outer side surfaces 32, 34 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.

In one embodiment, each clamp slide 52 is constructed and arranged to be connected to and positioned on its associated clamp slide pin member 54. In one embodiment, the clamp slide 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 configured and arranged to extend generally radially in the housing member 58 to enable the clamp slider pin members 54 to move radially (e.g., radially up and down) in the corresponding openings 56 in the housing member 58. In one embodiment, the housing member 58 may be any member that is 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 surface 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 configured 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 configured and arranged to receive a fastening member to connect the connecting 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 enable connection between the clamp slider pin member 54 and the link member 60. In one embodiment, the opening of the housing member 58 is also constructed and arranged to effect movement of the connecting member 60 as the clamp is moved between its retracted and extended positions. In one embodiment, the connecting member 60 is an elongated member formed with an opening at an end portion thereof. In one embodiment, the end portion of the connecting member 60 has a generally circular configuration to effect movement of the connecting member 60 as the clamp is moved 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 notch constructed and arranged to effect a connection between the connecting 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 when the clamp is moved between its retracted and extended positions.

In one embodiment, the actuator member 62 is constructed and arranged to be connected 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 appreciated by those skilled in the art. In one embodiment, the actuation 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 fig. 3 and 4). Two guide rods 68 also serve as pivot points for the

hinge segments

46 and 48. In this way, the

housing segments

46 and 48 and the actuating member segments 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 surface of the

tubes

12, 14, to an extended position (shown in fig. 6) in which the clamp is configured to apply a clamping force on the outer surface of the

tubes

12, 14 by actuation of the actuator 64. In one embodiment, axial movement of portions of the actuator 64 in turn causes axial movement of the 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 cylinder of the actuator, the fluid pressure applied, and the size of the various components of the clamp can be varied to control the clamping force that the clamp applies 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 such that there is a small gap between the clamp slider 52 and the tube when the actuating member 62 is retracted, 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 the actuator 64. The radial force on the tube at the clamp slide may be 10 times greater than the force generated by the actuator.

In one embodiment, the one or more processors 26 are configured to alter the interface area 38 between the

tubes

12, 14 prior to the welding operation by actuating the first tube clamp 16 and/or the second tube clamp 18 to change the roundness (or ovality) of the first tube 12 and/or the second tube 14 based on predetermined data (e.g., pre-weld profile data for the interface area 38). For example, in one embodiment, the one or more processors 26 are configured to alter the interface region 38 between the

tubulars

12, 14 prior to the welding operation by selectively driving one or more clamp sliders 52 of the clamps 16 and/or 18 to change the roundness of the first and/or

second tubulars

12, 16 based on the pre-weld profile data. In one embodiment, the minimum number of clamp sliders 52 is three. The number of clamp slides 52 may vary in other embodiments.

In one embodiment, all of the clamp slides of the first clamp always move together. In one embodiment, all of the clamp slides of the second clamp always move together. In one embodiment, each clamp is constructed and arranged such that all of its associated clamp sliders 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 clamp may change the roundness of one or both tubes (e.g., a first clamp may alter the roundness of a first tube to be welded and/or a second clamp may alter the roundness of a second tube to be welded). That is, the shape of a slightly out-of-round tube is changed to the shape of a more round tube. In one embodiment, for example, the clamp sliders 52 for either of the

clamps

16, 18 are symmetrically disposed and evenly circumferentially spaced around the exterior of the engaged tubular. Additionally, the innermost surface of each clamp slide may be equally spaced from the central axis of the clamp. Before the two clamps exert full clamping force, the profile of the interface region has not been fully determined due to the possibility of shape changes. The inspection detectors described herein may be used to determine the profile of the interface region and/or the weld joint after the clamp has been applied.

In one embodiment, a greater clamping force is used to open the two pivoting

clamp sections

46 and 48 of the clamp. In one embodiment, each clamp may include a latch mechanism 100 configured to hold the clamp (i.e., its pivotable/movable portion) in a closed position on the tube. In one embodiment, two locking pins are used to hold the pivoting

clamp sections

46 and 48 together. In another embodiment, the two pivoting

clamp segments

46 and 48 overlap at the interface where the two pivoting

clamp segments

46 and 48 contact. There is a concentric hole through the two overlapping portions. In one embodiment, a moveable pin or locking member 70 is located in one bore 72 and is configured to be actuated to extend from the bore 72 into a second bore 74, as shown in fig. 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 actuating member 62 of the clamp is also divided into three segments. Each section of the actuating member 62 corresponds to one of the three

clamp housing sections

44, 46 and 48. In one embodiment, as with

clamp housing sections

46 and 48, at the interface where the two pivoting actuation member sections come into contact, the two sections of the pivoting actuation member sections also overlap. In one embodiment, there is one concentric hole through both overlapping portions.

In one embodiment, referring to fig. 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 holes in the overlapping portions. In one embodiment, the pin actuator may make additional strokes remaining after the two actuator ring segments have been locked together by the pin member 76. As such, pin member 76 may move with actuating member 62 when actuating 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. Fig. 10 shows the movable pin member 76 in its extended position and the actuator member 62 in its unengaged position, and fig. 11 shows the movable pin member 76 in its extended position and the actuator member 62 in its engaged position. Comparing fig. 10 with fig. 11, it can be clearly seen that the pin actuator has an additional stroke (in fig. 10) remaining after the two actuating ring segments have been locked together by the pin member 76. This additional travel of the pin actuator remaining after the two actuating 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.

Fig. 12-17 show another embodiment of the clamp 16 'or 18'. In one embodiment, the construction and operation of the clamp of fig. 12-17 is similar to that of the clamp of fig. 3-11, except for the differences noted below.

The clamp 16 'or 18' of fig. 12-17 is also divided into three sections: a top fixed/non-pivoting portion 44' and two bottom pivotable portions 46' and 48'. The two bottom pivotable portions 46 'and 48' are hinged such that the two bottom pivotable portions 46 'and 48' can be swung open to allow the clamp to be placed on and removed from the tube. In one embodiment, a linear actuator is used to control the position of each movable/pivotable clamp portion. In one embodiment, the actuator is an electrical actuator. Fig. 12 shows the two bottom pivotable portions 46 'and 48' of the clamp in the closed (and locked) position, while fig. 13 shows the two bottom pivotable portions 46 'and 48' of the clamp in the swung open position. That is, the two bottom pivotable portions 46' and 48' of the clamp may be adapted to pivot radially outward such 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 be swung into a closed (and locked) position.

In one embodiment, the clamp 16' or 18' includes a plurality of clamp slides 52' (e.g., 4 or more clamp slides) to clamp and shape the tube. In one embodiment, the clamp slide 52' may be interchangeable for different sized tubes. In one embodiment, each tube is sized with a corresponding slider size. In one embodiment, the clamp slide 52' is mounted in an angled guide 78. In one embodiment, the angled guide 78 is fixedly connected to the clamp housing. As shown in fig. 14 and 16, when the clamp slide 52 'is positioned at one end 80 of the angled guide 78, the clamp slide 52' is in its retracted position. As shown in fig. 15 and 17, when the clamp slide 52 'is positioned at the other end 82 of the angled guide 78, the clamp slide 52' is in its engaged position. The angled guide 78 is constructed and arranged to taper downwardly from an end 80 to an end 82. In one embodiment, each clamp slide 52 'is moved by a linear actuator 64' (e.g., hydraulic, pneumatic, or electric) along its respective angled guide 78 between ends 80 and 82.

In one embodiment, as shown in fig. 16 and 17, the clamp blocks 52' have interlocking features to ensure that all of the clamp blocks 52' travel the same distance along their respective angled guides/tracks, and thus all of the clamp blocks 52' are 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 tongue 84 of the clamp slider 52' is configured to slide into interlocking connection with the prongs 86 of an adjacent slider 52 ". In one embodiment, each clamp slide 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 broach holder is described in detail, for example, in U.S. patent No. 6,109,503, which is incorporated by reference in its entirety in this patent application.

In one embodiment, the system 10 may further include a sensing system configured to monitor the clamping force generated by the clamp such that the clamp does not generate a clamping force to squeeze 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 may be avoided by limiting the pressure used to actuate the clamp. The pressure limit is a function of the tube yield strength, the tube diameter, and the tube wall thickness. In one embodiment, the values for the tube yield strength, the tube diameter, and the tube wall thickness are input into one or more processors. The one or more processors are configured to process the received values of the tube yield strength, the tube diameter, and the tube wall thickness, and calculate the correct pressure values. This calculated pressure value may 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, once all of the gripper slides are brought into contact with the pipe, permanent deformation of the pipe can be avoided by stopping the gripping. To do this, one or more processors need to know when all of the gripper blocks have been in contact with the tubing. In one embodiment, a contact sensor may be used to determine when all of the gripper slides have contacted the pipe.

In one embodiment, a non-contact sensor, such as a proximity switch, may be mounted to each clamp slide. When the distance between the gripper slider and the pipe stops changing, the gripper slider is already brought into contact with the pipe. This constant value can be checked on the basis of values recorded from previous clamping operations or predetermined target values. This ensures that the clamps have indeed come into contact and have not traveled their stroke before coming into contact.

In one embodiment, a contact switch, such as a single pole double throw switch, may 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 sensor, such as a load cell, or an indirect load sensor, such as a strain gauge, may be mounted to each clamp slide. When all of the sensors report a non-zero value of change, then the gripper slides are all in contact with the pipe.

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 welding torch may be configured with additional travel to ensure the start and end of the weld overlap. In one embodiment, the welding torch may be configured with additional travel to cover the distance between the joint sensing laser and the welding torch.

In one embodiment, the welding torch 20 is configured to apply multiple overlapping passes without stopping and restarting. In one embodiment, the welding torch 20 is configured to perform a plurality of 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, pulsed multi-control (PMC), and Low Spatter Control (LSC).

In one embodiment, the welding torch 20 is configured to be mounted to a circular rail member 88, as shown in fig. 18 and 19. The rail member 88 is configured to be placed around one of the first and second pipe clamps 16, 18 such that the welding torch 20 is positioned between the first and second pipe clamps 16, 18 and in line with the interface area 38 between the

pipes

12 and 14 and/or the weld joint 36 to be welded.

In one embodiment, the track member 88 is divided into three sections: a top fixed/non-pivotable portion 90 and two bottom

pivotable portions

92 and 94. The two bottom or side

pivotable portions

92 and 94 are configured to hingedly/pivotably connect to the top fixed/non-pivotable portion 90 such that the two

pivotable portions

92 and 94 can be swung open to allow the rail member 88 (with the inspection detector 22 and the welding torch 20) to be placed on and removed from the pipe. In one embodiment, a linear actuator 96 may be used to control the position of each

movable clamp segment

92 and 94. In one embodiment, an electric, mechanical, hydraulic, pneumatic, or any other type of linear actuator may be used.

In one embodiment, the rail member 88 further includes a latch mechanism 98 configured to retain the rail member 88 in a 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 fig. 7 and 8 and described with respect to fig. 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 rail member 88 is configured and sized such that an inner surface 102 of rail member 88 is positioned about an outer surface 104 of a portion 106 of

clamp

16 or 18. In one embodiment, the rail member 88 includes two openings 108 on its fixed/non-pivotable portion 90. In one embodiment, 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 there is no axial movement of the rail member 88 relative to its associated clamp.

Fig. 18 shows the two bottom

pivotable portions

92 and 94 of the track member 88 in the closed (and locked) position, while fig. 19 shows the two bottom

pivotable portions

92 and 94 of the track member 88 in the swung open position. That is, the two bottom

pivotable portions

92 and 94 of the track member 88 may be adapted to pivot radially outward such that the track member 88 may swing open to allow the tube to be positioned under the non-pivotable portions. When the tube is in place, the two bottom

pivotable portions

92 and 94 of the rail member 88 can be swung into a 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 having 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 absolute encoders configured to determine the exact position of all modules (torch module 126 (including torch 20), grinder module (including grinder 30), and inspection module (including inspection detector 22 and/or inspection camera 182)) that are always traveling on the track member 88. 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 (e.g., an X-axis, a Y-axis, and a Z-axis). In one embodiment, the welding torch 20 may include three absolute position encoders, each configured to determine the position and/or orientation of the welding torch 20 along one of three mutually perpendicular axes (e.g., an X-axis, a Y-axis, and a Z-axis).

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

In one embodiment, the welding torch 20 is operably connected to a torch motor. In one embodiment, a torch motor is operably connected to one or more processors to control movement of the welding torch 20 along the weld joint during a welding operation. In one embodiment, the torch motor is described in detail in international patent application No. PCT/US2015/062558, filed 24/11/2015, which is incorporated by reference in its entirety into this patent application.

In one embodiment, the one or more processors 26 are further configured to interact with the inspection detector 22 and/or the inspection camera 182 to scan the interface region between the

pipes

12, 14, to determine the profile of the interface region between the

pipes

12, 14 before, during, and after a welding procedure, to generate pre-weld profile data, dynamic weld profile data, and post-weld profile data based on the scanned data, and to control the external welding system and/or its operation based on the generated pre-weld profile data, dynamic weld profile data, or post-weld profile data.

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

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

It will be appreciated that in view of the slight disparity in tube structure, an absolutely perfect alignment is often (and often not) achieved. Nevertheless, such perfect alignment is not necessary as long as the alignment is within tolerances 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 minimum diameter, the location and size of the maximum diameter, the average diameter of the tube, the average wall thickness of the tube, the location and size of the minimum wall thickness, and/or the location and size of the maximum wall thickness. In one embodiment, the tube ovality/roundness data may include a comparison between each of the location and size of the minimum diameter, the location and size of the maximum diameter, the location and size of the minimum wall thickness, and the location and size of the maximum wall thickness, and their respective predetermined values. In one embodiment, the tube ovality/roundness data may include a comparison between each of the tube average diameter and the tube average wall thickness and their respective 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 groove profile data. In one embodiment, the tube groove profile data may include a tube groove geometry. In one embodiment, the pipe groove profile data may include a comparison between each of the size and shape of the pipe groove, the root (land) thickness of the pipe groove, the groove angle of the pipe groove, the offset of the pipe groove, and the root angle of the pipe groove, and their respective predetermined values. In one embodiment, based on the comparison, the pipe groove profile data may include pipe groove 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 fitting and alignment data. In one embodiment, the weld joint fitting and alignment data may include data regarding the gap between the inner abutting ends of the tubes (after alignment of the tubes). In one embodiment, the weld joint fitting and alignment data may include data regarding the gap between the bevels of the pipes (after pipe alignment). In one embodiment, the weld joint fit and alignment data may include the location and size of the minimum gap, the location and size of the maximum gap, and/or the average gap. In one embodiment, the weld joint fit-up and alignment data may include a comparison between each of the location and size of the minimum gap and the location and size of the maximum gap and their respective 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 a gap deviation of the pipe at all locations on the circumference of the pipe. In one embodiment, the weld joint fit and alignment data may include a minimum height difference between the tubes (e.g., 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 interface region between the tubes to determine a profile of the interface region between the tubes at a region of the interface before the weld material is deposited thereon during the welding procedure and to generate dynamic profile data. In one embodiment, the one or more processors are configured to generate a welding signal to control the welding torch based on the dynamic profile data. The dynamic profile data is described in detail below. The term "dynamic (on-the-fly)" as used herein also means or refers to "real-time," meaning that sensing or detection is used by one or more processors to control the welder during the current welding operation. Of course, because the torch is behind the inspection detector/inspection laser by a defined distance, some buffering (or slight time delay) occurs between the receipt of the profile data and the use of such data by the one or more processors 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 profile of the interface region and/or the weld joint after the welding operation.

In one embodiment, the post-weld profile data may include a profile of the formed weld bead. In one embodiment, the post-weld profile data may include a profile of the formed root pass weld layer. In one embodiment, the post-weld profile data may include weld shape characteristics such as mismatch, weld bead concavity, and re-entrant angle. In one embodiment, the one or more processors are configured to cause another welding operation to be performed on the interface region between the pipes 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 may be one of a variety of types. In one embodiment, additional welding operations are performed on top of the previous weld to remedy any weld defects. In another embodiment, defective welds may be ground by the grinder 30 or, alternatively, completely removed (manually or automatically) before any subsequent repair welding operations are performed.

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

In one embodiment, the weld head assembly comprises: a radial positioning system 116 (shown in fig. 21 and 22) configured to effect radial movement of the welding torch 20; an axial positioning system 118 (shown in fig. 23-25) configured to effect axial movement of the welding torch 20; and a tilt positioning system 120 (shown in fig. 26-28) configured to effect tilting movement of the welding torch 20.

In one embodiment, the welding torch 20 is mounted for radial movement by a 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 the 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 pipe 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 pipe 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 welding material deposited in the root pass weld and to 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 welding torch 20 to move radially to track changes in the shape of the tube, to adjust the distance of the welding tip of the multiple passes to the workpiece (e.g., tube) (e.g., root and hot pass welding procedures), and to retract from the tube when the welding system is not performing a weld. That is, during each weld pass, the radial positioning system 116 is configured to track deviations in the pipe diameter to maintain a constant distance between the torch tip and the weld joint/interface area between the pipes.

In one embodiment, the radial positioning system 116 is configured to provide a radial travel of about 1.25 inches for the welding torch 20. In one embodiment, the welding torch 20 is movable between a normal, non-extended, retracted configuration and an extended configuration by the radial positioning system 116. Referring to fig. 21 and 22, the welding torch 20 has been extended (to its extended configuration) by the radial positioning system 116 such that the welding torch 20 is positioned at the correct/desired/predetermined distance from the pipe to perform the welding procedure. Fig. 22 shows the welding torch 20 moved (by the radial positioning system 116) to a retracted position where the welding torch 20 is away from the tube to prevent damage when moving from one weld joint to the next. Fig. 21 shows the welding torch 20 moved (by the radial positioning system 116) to a welding position where the welding torch 20 is positioned at the correct height to perform a 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 (e.g., mechanically coupled) to rotate the lead screw. In one embodiment, the motor is configured to rotate in a clockwise or counterclockwise direction to raise or lower the welding torch 20 substantially parallel to a radial axis R-R (shown in fig. 21 and 22) of the

tubes

12, 14. In one embodiment, the motor is configured to be directly coupled to rotate the lead screw. In another embodiment, the motor is configured to rotate the lead screw, for example indirectly through a series of gears or a gearbox. 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 thread onto the lead screw and includes complementary threads machined on an inner surface thereof. 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 with the lead screw. That is, the lead nut is restricted from rotating with the lead screw, and thus 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 configured to transfer the 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 thread. In one embodiment, the direction of movement of the lead screw nut is dependent on the direction of rotation of the lead screw of the motor. When the lead nut is interlocked in the opening of the radial positioning member, the radial positioning member is configured to advance/move (up or down) the lead screw with the lead nut. The slidable engagement between the radial positioning member and the guide bar member also facilitates such (up or down) travel/movement of the radial positioning member.

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

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

Fig. 23 and 25 show the torch 20 moved along the axis of the tube (by the axial positioning system 118) to left and right axial positions, respectively. In one embodiment, the axial positioning system 118 is configured to move the welding torch 20 about two inches along the axis of the tube to align with the weld joint groove. During the welding procedure, the axial positioning system 118 is configured to oscillate the welding torch 20 across the weld joint (and within the weld groove to completely fill the groove, if necessary) at a frequency of up to 4Hz, with 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 screw nut is driven along the threads as the lead screw is rotated by the motor. In one embodiment, the motor is configured (e.g., mechanically coupled) to rotate the lead screw. In one embodiment, the motor is configured to rotate inbase:Sub>A clockwise or counterclockwise direction to cause left or right side movement of the welding torch substantially parallel to the axial axisbase:Sub>A-base:Sub>A of the tube (as shown in fig. 23-25). In one embodiment, the motor is configured to be indirectly connected to rotate the lead screw, for example, through a series of gears. That is, the motor includes an output shaft, and the motor is operatively connected to the lead screw through a gear that engages the output shaft of the motor. In one embodiment, a first gear is connected to the output shaft of the motor, a 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 to a lead screw through a gear, which rotates when the motor is operated. In another embodiment, the motor is configured to be directly connected (i.e., 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, the lead nut is restricted from rotating together with the lead screw, and thus 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 weld application point. In one embodiment, such a positioning system is described in detail in international patent application No. PCT/US2015/062558, filed 11/24/2015, which is incorporated by reference in its entirety in this patent application. In fig. 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 about a point radially outward from the welding point by the tilt positioning system 120. This configuration changes the distance between the point measured by the laser/inspection detector 22 and the weld application point. In one embodiment, the one or more processors 26 are configured to calculate the distance between two points and compensate accordingly.

In one embodiment, the angular positioning system 120 is configured to enable the welding torch 20 to vary its angle of inclination in the plane of travel to account for changes in the direction of welding relative to the direction of gravity. In one embodiment, the angle of inclination of the welding torch 20 may be varied to accommodate gravity. In one embodiment, the tilt angle of the welding torch 20 may be adjusted to compensate for the 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 (i.e., not just gravity).

Since the torch can articulate during the welding operation, it can take into account the gravitational forces acting on the weld pool as it rotates around the stationary tube. Specifically, the angle of the torch may be changed by operation of at least one torch motor (i.e., a tilting torch motor) based on whether the torch travels upward against gravity or downward with gravity. One or more motors (e.g., a tilting torch motor) may also change the torch angle within the plane of rotation based on a particular position within the upward or downward stroke of the torch. 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 disposed in a fixed position given, for example, that it will travel downward only by gravity. In some embodiments, as described above, the present patent application contemplates that welding may be accomplished while the welding torch is moved up (against gravity) or down (by gravity). In addition, the welding torch 20 may articulate based on different rotational positions (e.g., a welding operation performed 10 degrees from top dead center may, in an ideal situation, have slightly different requirements than a weld performed 90 degrees from top dead center due to, for example, gravity applied to the weld pool and the tendency of the weld pool to adhere to the pipe surface in different ways at different locations on the pipe to be welded.

In one embodiment, the welding torch 20 may be configured with a continuously variable torch tilt angle to compensate for or accommodate a continuously varying orientation of the welding torch due to gravity. In one embodiment, the welding torch 20 may be configured to gradually change the torch tilt angle based on where the welding torch is located (i.e., where the welding torch is welding along the circumference). 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 a different torch inclination angle for each 90 °,30 °,60 °, or 120 ° rotation.

In one embodiment, the tilt positioning motor angularly articulates the welding torch 20 generally in a 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.

FIG. 27 shows the torch 20 positioned in a normal, non-tilted position. In one embodiment, the tilt positioning system 120 is configured to provide an angular tilt of +/-10 ° to the welding torch 20. In one embodiment, the tilt positioning system 120 is configured to provide an angular tilt of +/-5 ° to the welding torch 20. For example, as shown in fig. 26 and 28, the welding torch 20 has been moved to a-5 ° or +5 ° angle tilt, respectively, by the tilt positioning system 120 so that the welding torch 20 is positioned at the correct/desired/predetermined distance from the pipe to perform the weld. In another embodiment, the tilt positioning system 120 is configured to provide an angular tilt of +/-7 ° to the welding torch 20. In one embodiment, the tilt positioning system 120 is configured to provide an angular tilt to the welding torch 20 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 as shown in fig. 53 and 54. That is, the arc angle between the welding location measured by the laser/inspection detector 22 and the welding location welded by the welding torch is constant. In one embodiment, the one or more processors 26 are aware of the constant arc distance between the pivot point P (e.g., welding tip) and the checkpoint such that the one or more processors 26 are configured to control the articulation and pivoting movement of the welding torch 20 based on pre-weld profile inspection data or dynamic inspection data.

The configuration of the welding torch 20 that enables 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 particularly useful for welding systems having multiple torches, for example. In one embodiment, the welding torches do not change their angles simultaneously, in which case it would be advantageous to change the angle of the welding torch without any adverse effect on itself or other welding torches.

In one embodiment, the tilt positioning system 120 includes a tilt torch motor, a rail member 122, and a guide roller 124. In one embodiment, the rail member 122 is configured to engage with a guide roller 124 to facilitate the angled positioning of the welding torch 20. In the illustrated embodiment, the guide rollers 124 may include two upper guide rollers and two lower guide rollers. In one embodiment, the bevel positioning system 120 includes a 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 (e.g., mechanically coupled) to rotate a gear. In one embodiment, the motor is configured to rotate in a clockwise or counterclockwise direction to cause forward or rearward tilting movement of the welding torch 20. In one embodiment, the tilt torch motor is configured to be coupled to the rail member 122, for example, by gears. That is, the tilting torch motor includes an output shaft, and the gear is connected to the output shaft of the motor. The tilting torch motor is connected to the rail member 122 by a gear, and the rail 122 moves when the tilting torch motor is operated.

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

In one embodiment, the external welding system (with torch 20) is configured to receive welding profile data (e.g., before, during, and after a welding procedure) from an inspection system (e.g., with inspection detector 22 and/or inspection camera 182), and is configured to move its external torch 20 and/or tilt its external torch 20 to achieve full weld penetration based on the received welding profile data. Thus, the weld profile data from the inspection system may be used by an external welding system to enable optimal welding.

In one embodiment, the motor directing the inspection detector 22 also rotates the welding 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, the radial positioning system 116, the axial positioning system 118, and the tilt positioning system 120 therein. In one embodiment, the torch housing assembly is configured to protect components of the torch 20 and various components of its axial, radial, and/or angular positioning system from welding heat and spatter.

In one embodiment, referring to fig. 29, the torch 20 in combination with the radial, axial, and

tilt positioning systems

116, 118, and 120 comprise a 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 welding torch 20 around the interface region 38 between the

tubes

12, 14. In one embodiment, the carriage is configured to travel along a 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 of the drive motor is configured to mesh with an 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 at 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 the guide roller 130. In one embodiment, rail member 112 of rail member 88 is configured to engage guide roller 130 to facilitate positioning of torch module 126 on rail member 88. In the illustrated embodiment, the guide rollers 130 may include an upper guide roller and a lower guide roller. In one embodiment, the travel motor 128 is configured (e.g., mechanically coupled) to rotate the gear 132. In one embodiment, the travel motor 128 is configured to rotate in a clockwise or counterclockwise direction to cause forward or rearward movement of the torch module/funny frame. In one embodiment, the travel motor 128 is configured to be connected to the track member 112, such as by a 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 through a gear 132, and the rail member 112 moves when the motor is operated. In one embodiment, the rail member 112 is configured to guide upper and lower guide rollers 130. In one embodiment, the upper and lower guide rollers 130 are biased against the guide rail member 112 such that the upper and lower guide rollers 130 are configured to enable movement of the torch module 126 along the circumference of the guide rail member 88.

In one embodiment, each torch module 126 is configured to be independently positioned anywhere around the circumference of the pipe and move at any speed within its capabilities regardless of the travel speed of any other torch. In one embodiment, the weld 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 weld joint. This may be due to a number of reasons. For example, when a pipe heats or cools, the weld joint may change shape during the weld pass. Due to the variability of the machining, the shape of the groove may vary at different locations along the circumference. The height of the 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 weld possible.

In one embodiment, an inspection detector 22 (e.g., a laser) may be mounted on each torch module to dynamically measure the joint profile before the start of welding 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 position of the welding torch. In one embodiment, the inspection detector 22 is configured to measure the width and depth of the weld groove. In one embodiment, the 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 weld joint position measured by the inspection detector 22 and the joint position welded by the welding torch is constant, as shown in fig. 53 and 54.

As the torch oscillates within the weld recess, the arc voltage varies with the distance between the torch tip and the weld recess. 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, a short distance along the circumference from the weld. In one embodiment, the inspection camera 182 is configured to be oriented to view the weld point and the torch tip relative to the weld groove. In one embodiment, inspection camera 182 may be configured to be mounted in conjunction with inspection detector 22 such that it is aimed at the same point on the tube outside surface 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 the temperature of the pipe, GPS location, or ambient temperature. In one embodiment, the external welding system 10 is configured to receive instructions from a remote system that may include, but is not limited to, welding parameters and procedures (e.g., wire feed speed, welding current, welding voltage, welding travel speed, oscillation distance, oscillation rate), updates to control methods, and reports of inspection go/no-go. In one embodiment, such a remote system is described in detail in international patent application No. PCT/US2015/062558, filed 24/11/2015, 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 tube clamp 16 and the second tube 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 fig. 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 tube) between the first tube clamp 16 and the second tube clamp 18. That is, the first and second tube clamps 16 and 18 are each positioned on axially opposite sides of the inspection detector 22 and/or the inspection camera 182.

In one embodiment, the inspection detector 22 may include an inspection laser, a three-dimensional (3D) inspection camera, an inspection ultrasonic sensor system, an inspection capacitance probe, and any other inspection detector, as will be understood by those skilled in the art. In the case of using a laser, 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 smart laser sensor SLS-050 manufactured by Meta Vision Systems inc.

In one embodiment, the inspection detector 22 includes an emitter for emitting an inspection radiation beam and a receiver for receiving an inspection signal from the reflected radiation. In one or more embodiments, the receiver of the inspection detector includes a sensor that detects the 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 weld 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 height of the adjacent tube surfaces at the area to be welded, the relative spacing between the tubes, any non-uniformity in the adjacent surfaces to be welded (e.g., at their bevels).

In addition, because the inspection detector scans along the entire interface between the tubes and/or the entire weld joint between the tubes, a particular interface profile and/or a particular weld profile may be determined at any particular region of the scan. This information may also be used by the one or more processors to control the operation of the welding torch to provide a customized/adjusted weld that is specifically adjusted for the structural profile of the pipe to be welded at its interface region. This information may also be used by one or more processors to control the operation of the grinding machine 30 to provide customized/adjusted grinding specifically tailored to the structural profile adjustment of the welded pipe.

In one embodiment, an inspection detector motor is operatively associated with the inspection detector 22 to direct an inspection radiation beam along an interface region 38 between the

pipes

12, 14 to be welded and a weld joint 36 between the

pipes

12, 14.

In one embodiment, the inspection detector includes a motor that drives the inspection detector along the weld joint. In one embodiment, the welding torch is configured to be attached 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 weld 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 a welding procedure and also provide pre-weld data. In one embodiment, the other of the two inspection detectors may be a tail inspection detector configured to be behind the welding torch and provide post-weld data during a welding procedure. In one embodiment, the angle between each inspection detector and the welding torch may be adjustable.

In one embodiment, the inspection camera 182 and the inspection detector 22 are operably connected to the one or more processors 26. In one 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 wirelessly. In another embodiment, the 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 will be appreciated that where multiple torches are provided, multiple inspection detectors/lasers may also be provided.

In one embodiment, the computer system and its one or more processors 26 may be located in the system 10. In another embodiment, the computer system and its processor(s) 26 may be located remotely from the system 10. In one embodiment, the one or more processors 26 may include a digital processor, an analog processor, a digital circuit designed to process information, an analog circuit designed to process information, a state machine, and/or other mechanisms for electronically processing information.

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

In one embodiment, system 10 does not include access poles/connections, and may include a maneuver connection that connects system 10 to a deployment system (e.g., a truck). In one embodiment, the steering linkage is not a rigid linkage. In one embodiment, an off-board processor may also refer to an electronic device that is tethered to the on-board system through a non-rigid navigation connection and is located locally at the job site. That is, if the processor moves with a non-rigid steering linkage, it may also be considered an "on-board" processor.

In one embodiment, the one or more processors 26 are also configured to secure the welding system 10 against movement at a location on the

pipes

12, 14 that positions the inspection detector 22 relative to the interface region 38 to enable the inspection detector 22 to detect the profile of the interface region 38 between the

pipes

12, 14. In one embodiment, the one or more processors 26 are also configured to secure the welding system 10 against movement at a location on the

pipes

12, 14 that positions the inspection detector 22 relative to the weld joint 36 to enable the inspection detector to detect the weld profile between the

pipes

12, 14.

The term "motor" as used herein broadly refers to any type of electromechanical motor, such as, for example only, an electric motor, a hydraulic motor, a pneumatic motor.

In one embodiment, the system 10 may include a feedback system (e.g., using the inspection detector 22, the one or more processors 26, the motors (including the axial, tilt, and radial positioning motors of the welding torch; the axial, tilt, and radial positioning motors of the grinder; the motors of the inspection detector/camera), the first and

second clamps

16 and 18, the welding torch 30, as will be described in detail below) configured to sense whether the ends of the first and

second tubes

12 and 14 are properly aligned.

Fig. 30 shows a grinding mill 30 according to an embodiment of the present patent application. As shown in fig. 30, the grinder 30 is positioned to grind the weld start position, 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 weld can be blended. After the weld stop point has been blended to the weld start point, the weld point may be ground again to provide a consistent surface height for the next weld point. In one embodiment, after all welds are complete, the grinder 30 may also grind the entire circumference of the weld to smooth the final surface of the weld.

In one embodiment, referring to fig. 30-33, the grinder module 140 includes a grinding head 30, an axial positioning system 152, a radial positioning system 144, an inspection detector 22 (e.g., a 3D scanner), and one or more processors 26. In one embodiment, the abrading head 30 includes a motor 146, a gear box 148, and an abrading member/disc 150. In one embodiment,

positioning systems

144 and 152 include axial motor 156, axial guide 160, radial motor 168, radial guide 176, and radial spring 178. In one embodiment, grinder module 140 further 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 (shown in fig. 31 and 32) of the grinding machine 30 is configured to effect radial movement of the grinding or abrading machine 30, and the axial positioning system 152 (shown in fig. 33) is configured to effect axial movement of the grinding machine 30. In one embodiment, the grinding machine 30 may further include a tilt positioning system configured to effect a tilting movement of the grinding machine 30. In one embodiment, the structure and operation of the grinder's tilt positioning system may be similar to that of the welding torch 20 (described above in this patent application).

In one embodiment, the radial positioning system 144 is configured to move the grinding mill 30 to any radial distance required for grinding. In one embodiment, the radial movement of the grinder 30 may be spring loaded such that the grinder 30 applies a consistent force to the surface of the tube (of the weld joint). In one embodiment, the radial positioning system 152 is configured to move the grinder 30 away from the surface of the pipe 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 disk 150 is configured to move toward and away from the welding surface of the pipe. 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 weld joint between the grinding disk 150 and the

tubes

12, 14. In one embodiment, the radial positioning system 144 of the grinding mill 30 is configured to retract the grinding mill 30 away from the tube to prevent damage when moving from one grinding location to the next. In one embodiment, the grinder 30 may be moved between a grinding configuration and a lifting configuration by a radial positioning system 144.

In one embodiment, the radial positioning system 144 of the grinding mill 30 is configured to allow the grinding mill 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 abrasive disk 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 (e.g., tube) and retract away from the tube as the grinder 30 travels. That is, during each grinding procedure, the radial positioning system 114 is configured to track the deviation of the weld bead/joint so as to maintain a constant distance between the grinding disc and the weld joint.

In one embodiment, the radial positioning system 144 may include a linear actuator. In one embodiment, referring to fig. 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, motor 168 is configured (e.g., mechanically coupled) to rotate lead screw 170. In one embodiment, motor 168 is configured to rotate in a clockwise or counterclockwise direction to raise or lower welding torch 30 substantially parallel to a radial axis R-R of the tube (as shown in fig. 21 and 22). In one embodiment, motor 168 is configured to be directly coupled to rotate lead screw 170. In another embodiment, motor 168 is configured to be indirectly connected, such as through a series of gears or gear boxes, to rotate lead screw 170. In one embodiment, the 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 thread onto the lead screw 170 and includes complementary threads machined on an inner surface thereof. In one embodiment, the lead nut 172 is configured to interlock with a portion of the radial spring plate 174 such that rotation of the lead nut 172 is prevented along with the lead screw 170. That is, the lead nut 172 is restricted from rotating with the lead screw 170, and thus the lead nut 172 is configured to travel up and down the lead screw 170.

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

In one embodiment, the spring 178 is configured to push the grinding bit 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 bit 30 to facilitate radial movement of the grinding bit 30. As the grinding bit 30 contacts the weld point, the radial motor 168 continues to drive the radial spring plate 174 closer to the surface of the

tubes

12, 14. This compresses the spring 178 and increases the force of the grinding bit 30 against the weld. The spring 178 continues to urge the polishing head 30 against the weld point with minimal force reduction as the polishing head 30 removes the weld material.

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

Fig. 33 shows an axial positioning system 152 of the grinding mill 30. In one embodiment, the positioning system 152 includes a linear actuator having 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, lead screw 163 is fixedly attached to a grinder carriage frame (as described in detail below).

In one embodiment, the positioning system 152 includes a housing member 165 configured to move linearly (along axis L-L) as its internal hollow shaft motor 156 rotates the nut. That is, the lead screw 163 is fixed, and the nut is rotated by the motor 156 (i.e., built in the housing member 165), and therefore, 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 (along the axis L-L) with the housing member 165.

In one embodiment, the system 10 may include one or more grinders 30, each 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 a weld start point. For example, the welding start point may be ground using a hard disk 151 as shown in fig. 34. The system 10 may include another type of grinder configured to grind and clean the profile after the weld is complete. For example, the profile may be ground and cleaned after welding is complete using a wire wheel 153 as shown in fig. 35. In yet another embodiment, the system 10 may include a grinding wheel as shown in fig. 36 configured to grind portions of the weld 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 a weld start location of the weld joint 36. In one embodiment, the start of the weld is ground before the welding torch 20 completes the weld pass. Thus, the grinding procedure is performed while the welding torch 20 is performing a welding procedure. 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 point while grinding to create a gentle slope at the location of the start of the weld.

In one embodiment, the grinder is configured to grind at least one weld start position of the weld 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 (i.e., 0 degrees) up to 20 degrees. In one embodiment, it may be between 5 and 10 degrees of the end point of the weld.

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

In an embodiment, the grinder 30 is configured to grind at least one welding end position of the weld 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 (i.e., 0 degrees) up to 20 degrees. In one embodiment, it may be between 5 and 10 degrees of the end point of the weld.

In one embodiment, the grinder 30 is configured to grind an overlapping region between a start portion and an end portion of the weld joint.

In one embodiment, the grinder 30 is configured to grind the entire circumference of one of the plurality of welding material layers (e.g., a weld bead layer, including but not limited to a root weld layer, a hot weld layer, a fill and cap weld layer) prior to forming a subsequent welding material layer on top of the welding material layer. 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 welding torch is configured to form a 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 welding torch is configured to form a second layer of welding material on top of the ground first layer of welding material.

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

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

In one embodiment, the lapping machine 30 includes an inspection detector 22 (e.g., a laser) configured to measure the profile of the weld point prior to the beginning of the lapping procedure. 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 view along the weld joint to view the profile of the weld groove. In one embodiment, the images from the inspection camera 182 may be communicated to an operator/user for visual inspection. In one embodiment, the images from the inspection camera 182 may be processed by the one or more processors 26 to determine the profile of the weld joint.

In one embodiment, the location of the grinder 30 is determined based on the profile of the weld joint 36 between the

pipes

12 and 14. In one embodiment, the one or more processors are configured to determine characteristics of the welding profile and, based on the determined characteristics of the welding profile, send a signal to the grinder 30 to move to a particular location based on the characteristics of the welding profile at the particular location.

In one embodiment, the one or more processors 26 of the system 10 are configured to control the one or

more grinder motors

156, 168 to control the position and/or orientation of the grinder 30.

In one embodiment, the grinder 30 is configured to be mounted in a fixed position. If all of the weld passes begin at the same location around the circumference of the weld joint, the grinder 30 is installed 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 problems with the welding 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, the grinder 30 and all sensors and motors operating with the 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 disc 150 configured to grind at least the portion of the weld joint 36. As described above, in one embodiment, the abrasive member may be a hard abrasive disk 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, grinder module 140 is configured to be mounted on 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 (as shown in fig. 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 with its own travel capability such that the grinder module 140 may move independently of the welding module 126. In one embodiment, the rail mounted grinder may travel to any point on the circumference of the weld 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 modules 140 may be mounted on circular rails of the U-shaped channel 110. In one embodiment, the grinder module 140 includes its own travel motor 138 (as shown in fig. 31). In one embodiment, the travel motor 138 is configured to rotate/drive the grinder module 140 circumferentially (360 ° relative to the tube axis Y-Y in fig. 30) along the weld joint 36. In one embodiment, the travel motor 138 is configured to drive the grinder module 140 at least 360 ° relative to the tube axis Y-Y to complete a rotary continuous grind.

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 rail members 88 are configured to engage guide rollers to facilitate positioning of grinder modules 140. In the illustrated embodiment, the guide rollers may include an upper guide roller and a lower guide roller. In one embodiment, the travel motor 138 is configured (e.g., mechanically coupled) to rotate a gear. 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 connected to the rail member, for example, by a gear. 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 to the rail member by a gear, and the rail member moves when the motor is operated. In one embodiment, the guide rail member is configured to guide an upper guide roller and a lower guide roller. In one embodiment, the upper and lower guide rollers are biased against the guide rail member such that the upper and lower guide rollers are configured to enable movement of the torch module 140 along the circumference of the guide rail member 88. In one embodiment, each grinder module 140 is configured to be independently positioned anywhere around the circumference of the tube and moved at any speed within its capabilities. In one embodiment, the grinder 30, grinder module 140, and/or grinding program may be optional in the system 10.

Referring to fig. 37-39, the system 10 for welding two

tubes

12, 14 further includes an enclosure 200 configured to enclose the interface area 38 between the welding torch 20 (shown in fig. 21-27), the first and second tube clamps 16, 18 (shown in fig. 21 and 24), and the

tubes

12, 14. In one embodiment, the enclosure 200 is further configured to enclose the inspection detector 22. In one embodiment, the enclosure 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 one another, e.g., to form a framework. The framework generally provides the structural integrity and shape of the enclosure 200. In one embodiment, the frame 202 of the enclosure 200 is configured to support the system 10 when the system is not being lifted. In one embodiment, the enclosure 200 is configured and sized to enclose the welding torch 20 (shown in fig. 21-27), the first and second tube clamps 16, 18 (shown in fig. 21 and 24), and the interface area 38 between the

tubes

12, 14, which is entirely located therein.

In one embodiment, referring to fig. 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 204 vc. On each side of the enclosure 200 (i.e., viewing the front of the enclosure 200 in fig. 38), the frame members 204hf, 204hrc, and 204vc are all connected to one another to form a rectangular or square side frame. In one embodiment, an angularly oriented stiffening frame member 204ar may be connected to portions of the frame members 204vc and 204hf to further stiffen the side frame of the enclosure 200.

In one embodiment, the enclosure 200 further includes a rectangular or square top frame formed from four horizontally oriented top corner frame members 204hrc connected to one another. In one embodiment, the top frame of the enclosure 200 is further reinforced by a horizontally oriented reinforcing frame member 204hr. Four horizontally oriented reinforcing frame members 204hr are shown in the embodiment shown in fig. 39. In one embodiment, the enclosure 200 further includes a top panel 206 (shown in fig. 37) connected to four horizontally oriented top corner frame members 204hrc. In one embodiment, four horizontally oriented reinforcing frame members 204hr are connected to four horizontally oriented top corner frame members 204hrc and top panel 206 after top panel 206 is connected to 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 a rectangular/square shaped front frame and a rear frame 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 reinforce 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 be connected to corresponding vertically oriented corner frame members 204vc and corresponding horizontally oriented frame members 204ih to further reinforce the respective front and rear frames of the enclosure 200.

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

In one embodiment, the enclosure 200 includes a closure assembly 208l, 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 member 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, a bottom closure portion 218, and front and rear closure portions 220 of the enclosure 200 (only the front closure portion is shown in the figures, and the rear closure portion is a mirror image of the front closure portion).

In one embodiment, the

closure assembly

2081, 208r is configured to move between a closed position, as shown in figure 37, and an open position, as shown in figures 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, the

side closure portions

212, 214, 216, the bottom closure portion 218, and the front and rear closure portions 220. In one embodiment, the frame members 226 may have the same shape cross-section. In one embodiment, the frame member 226 may have a cross-section of a different shape. In one embodiment, the number, orientation, and positioning of the frame members 226 may vary.

In one embodiment, the front closure portions 220 (220 l and 220 r) of the

closure assemblies

2081, 208r together form a front closure of the enclosure 200. Likewise, the rear closure portions of the closure assembly together form a rear closure of the enclosure 200.

Each front closure portion 220 (2201 and 220 r) includes a half or semi-circular opening 222 that forms a full opening (as shown in fig. 37) when the front closure portions 220 (2201 and 220 r) are together (i.e., when the

closure assemblies

2081, 208r are moved to the closed position of fig. 37) to receive a tube therein. Similarly, each rear closure portion includes a half or semi-circular opening that forms a full opening to receive a tube therein when the rear closure portions are together (i.e., when the

closure assemblies

2081, 208r are moved to the closed position of FIG. 37).

In one embodiment, the top of the enclosure 220 includes a fixed top portion formed by the horizontally oriented top corner frame member 204hrc and the top panel 206 and a movable top portion. In one embodiment, the movable top portion comprises the top closure portion 210 of

closure assembly

2081 or 208r.

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

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

In one embodiment, the enclosure 200 may be lifted from one place to another by lift points 228 to provide an easily removable enclosure. In one embodiment, the enclosure 200 may be lifted and moved from one location 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 may be hoisted for placement on or removal from the tube.

As shown in fig. 1 and 2, the top fixing/non-pivoting portions 44 of the first and

second clamps

16, 18 are connected to each other using guide rods 40 (40 a, 40 b). In one embodiment, a portion of the enclosure 200 is constructed and arranged to be coupled to the stem 40 (40 a, 40 b). For example, referring to fig. 38 and 39A, a portion 230e of connector portion 230 is configured and arranged to extend downward (in the direction of arrow a) to connect to stem 40 (40 a, 40 b). 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 two non-pivoting guide rods 40 (40 a, 40 b). 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 and

second clamps

16, 18 when the first and

second clamps

16, 18 are not surrounding the

tubes

12, 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 disposed on a side closure portion 214 of a

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 comprise a guide member 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 welder. In one embodiment, the orbital welder is configured to mechanically rotate through 360 ° around the

stationary tubes

12 and 14 in a continuous process (or through 180 degrees in a double welding procedure). In one embodiment, the present application provides a rail 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 (e.g., a floor or ground) while the

tubes

12, 14 are not positioned in the enclosure 200.

In one embodiment, as shown in fig. 55-59, the ends of the enclosure 200 may have inverted U-shaped guides 502 to keep the system centered on the

tubes

12, 14 when the enclosure 200 is lowered or raised. Referring to fig. 55-59, the system of the present patent application also incorporates a guide 502 to assist in placing the enclosure 200 onto the

tubes

12, 14. The guide 502 is incorporated into the frame member 204 of the enclosure 200 and is tapered on the bottom edge so that when the system is lowered onto the

tubes

12, 14, the guide 502 tends to push the

tubes

12, 14 toward the center of the system. Referring to fig. 56, when the

tubes

12, 14 are near the center position, the guide 502 transitions from being tilted to being vertical. Referring to fig. 57, once the

tubes

12, 14 are centered, the vertical sides of the guide 502 hold them in place.

Referring to fig. 40 and 41, in one embodiment, the system 10 may include a partial or welding enclosure 300 configured to be placed only around the welding torch 20. In one embodiment, the system 10 may further 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 a 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 configured to compress and extend based on the depth of the weld. For example, the flexible member 304 may include a bellows.

In one embodiment, the bellows 304 is constructed and arranged to extend beyond the welding torch 20 when the system 10 is not welding. The support 306 of the bellows 304 is configured to contact the

tubes

12, 14 and stop moving as the welding torch 20 moves toward the

tubes

12, 14. As the welding torch 20 continues to move, the bellows 304 is configured to compress until the welding torch 20 reaches the correct distance from the

tubes

12, 14 to make the weld. 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 a small gap between the support 306 of the bellows 304 and the

tubes

12, 14.

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

integrated enclosures

200 and 300.

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 have been included in the system. This configuration provides a redundant method for ensuring that the torch is in a safe position before the guide rails 88 are opened or closed. Referring to fig. 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 regularly spaced ring of holes 198 so that one or more triggers 194 can be mounted anywhere on the rail 88. The trigger 194 is configured to activate one or more limit switches 192 when the carriage 134 is in a position to place the limit switch body 196 adjacent the trigger 194. In this manner, trigger 194 is configured to indicate when carriage 134 is in certain positions, as will be understood by those skilled in the art. The triggers 194 are configured to be used individually or in combination to define a location such as home, top, bottom, side, weld start, weld end, safety, or any other location 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 pick-up truck (as shown in fig. 42), such as one used as a wrecker. A large version of the system 10 may be carried by a tracked vehicle (as shown in fig. 43). In one embodiment, the system 10 may be installed at a fixed location, such as at a reel base or on an offshore pipelaying vessel. In such an embodiment, the system 10 stays in one place and the pipe moves through it. In another embodiment, the system 10 may be lifted by a small crane (as shown in fig. 44). In yet another embodiment, the system 10 may be lifted by a multi-axis robotic positioner (as shown in fig. 45).

In one embodiment, the system 10 may be configured to detect the position of the tube using a vision camera, an ultrasonic distance sensor, a laser camera, 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 to limit travel to slow speeds when the distance to the pipe is small (less than one foot). In one embodiment, the sensor may be mounted to the enclosure, the clamp, the rail, the lifting device, and/or the transport vehicle. In one embodiment, the sensing device may be deployed remotely, detecting the location of the target point on the system 10 and tube, and transmitting the measurements wirelessly or by wire to the deployment system.

In one embodiment, the weld joint/bead may be inspected. In one embodiment, after each weld pass is completed, the outer profile of the completed weld may be measured using an inspection detector or laser 22 used to guide the welding torch 20. In one embodiment, after each weld pass is completed, the outer profile of the completed weld may be inspected using an inspection camera or 2D camera 182. In one embodiment, the inspection camera or 2D 182 may be mounted in conjunction with the inspection detector or laser 22.

In one embodiment, after the final weld pass is completed, the eddy current transducer 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 traveling module (e.g., a welding or grinding module). In one embodiment, the eddy current system is configured to be mounted at a location where an inspection detector or laser of a traveling module (e.g., a welding or grinding module) is typically located. In another embodiment, the eddy current system is configured to be mounted adjacent to an inspection detector or laser of a traveling module (e.g., a welding or grinding module).

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

A surface crack may typically be detected if the crack is on the same side as the inspection is performed, whereas the crack may not be detected if the crack is on the opposite side of the inspection. For example, external inspection of the tube cannot detect internal defects unless the thickness of the tube is small (e.g., less than about 1/8 "), or unless the tube is made of a non-ferromagnetic material. Non-ferromagnetic materials include stainless steel (e.g., 300 series) and other CRA materials.

In one embodiment, the eddy current system and inspection detector (laser and/or camera) are used together as a complementary inspection technique. For example, in one embodiment, the eddy current system is configured to detect or inspect features of the weld joint that are not easily detected or inspected by the inspection detector or laser. For example, an inspection detector (laser and/or camera) is configured to inspect the shape of the weld, while an eddy current system is configured to inspect weld cracks/defects including, but not limited to, copper cracks/defects, burn cracks/defects, misfire (including LCP/IWM misfire or Pore/IWM misfire) cracks/defects, lack of internal fusion (or non-fusion) cracks/defects, cluster porosity cracks/defects, copper/CP cracks/defects, and the like.

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

In one embodiment, the two tube clamps of system 10 are configured to enable transfer of a tube alignment load from one tube to another tube through the connection between the tube clamps. Otherwise, it is possible to use only one clamp to support all the equipment (e.g., the rails and various modules). In one embodiment, 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 weld 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 begin the next joint. In one embodiment, welding at an existing joint may be accomplished using a simpler system having only one clamp. This one clamp system provides better access to the weld and places fewer constraints on the space on the tool that is to be operated on the weld. Since this one fixture system applies the final pass, one fixture system includes an inspection tool mounted thereon to inspect the final weld produced by the final pass procedure.

In one embodiment, as described above, system 10 uses two clamp arrangements at least during the holding procedure of the pipe (including the alignment of the pipe and the forming procedure of the pipe) and during the previous one or two passes. Thereafter, the alignment of the two

tubes

12, 14 does not change. At this time, it is possible to complete the welding at the existing joint using only one jig.

In one embodiment, the system 10 is configured to inspect the formed weld 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 profile of the interface region and/or the weld joint after the welding procedure to obtain post-weld data. In one embodiment, the one or more processors are configured to cause a grinding procedure to be performed (by a grinder) on the formed weld 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 profile of the interface region and/or the weld joint after the grinding procedure to obtain the ground data. The post-grinding data may 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-grind profile data.

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

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

In one embodiment, the one or more processors are configured to cause another welding operation (prior to 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 weld 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 in-line with the interface area between the

tubes

12, 14 and/or the weld joint 36.

In one embodiment, the one or more processors are configured to control the grinding machine to wait a predetermined period of time after a welding procedure is completed at a location and before the grinding procedure 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 weld bead/joint produced by the welding torch at a location prior to the grinding procedure performed by the grinder at that location. In one embodiment, the positioning between the welding torch and the grinder is controlled by one or more processors.

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

In one embodiment, the grinder 30 is radially positioned based on a predetermined (grinder butt weld) pressure. In one embodiment, the one or more processors may be configured to sense pressure. In another embodiment, the one or more processors may be configured to determine the pressure/force by the relative positioning of the telescoping grinder parts/components and the spring constant. In one embodiment, the one or more processors may determine (grinder butt 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 the tilt sensor, the motor encoder, and/or the limit switch. In one embodiment, the one or more processors are configured to determine the location of all travel modules (including the torch module, the inspection module, and the grinder module) on the rail member at any given time based on this information.

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

In one embodiment, the system 10 may include a grinder debris control system. For example, in one embodiment, a grinder debris control system may include a shroud configured to enclose a grinder to contain dust and debris generated during a grinding procedure. In one embodiment, the shroud may include a vacuum port such that dust and debris may be drawn out of the shroud using a vacuum system. In one embodiment, the grinder debris control system may include a vacuum system. In one embodiment, the vacuum system is configured to be entirely contained on the grinder module.

In one embodiment, the torch module of the present application may include a plurality of torches. For example, in one embodiment, the 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 process may be performed by an internal grinder positioned within the tube while welding is performed from outside the tube. In one embodiment, the mill may be supported by a mill holder positioned within the tube.

Although the present application has been described in detail for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that the application is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. In addition, it is to be understood that this 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

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.