US20200306858A1 - Welding tool - Google Patents
Welding tool Download PDFInfo
- Publication number
- US20200306858A1 US20200306858A1 US16/372,311 US201916372311A US2020306858A1 US 20200306858 A1 US20200306858 A1 US 20200306858A1 US 201916372311 A US201916372311 A US 201916372311A US 2020306858 A1 US2020306858 A1 US 2020306858A1
- Authority
- US
- United States
- Prior art keywords
- welding
- locating device
- welding tool
- extended position
- tool
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000003466 welding Methods 0.000 title claims abstract description 171
- 238000000034 method Methods 0.000 claims description 20
- 230000003213 activating effect Effects 0.000 claims description 11
- 238000012360 testing method Methods 0.000 description 10
- 230000035515 penetration Effects 0.000 description 6
- 230000008569 process Effects 0.000 description 5
- 230000008878 coupling Effects 0.000 description 3
- 238000010168 coupling process Methods 0.000 description 3
- 238000005859 coupling reaction Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 238000004590 computer program Methods 0.000 description 2
- 230000001747 exhibiting effect Effects 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 230000009471 action Effects 0.000 description 1
- 230000004913 activation Effects 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 230000006399 behavior Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000009849 deactivation Effects 0.000 description 1
- 230000006870 function Effects 0.000 description 1
- 230000036541 health Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000009864 tensile test Methods 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/02—Seam welding; Backing means; Inserts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K9/00—Arc welding or cutting
- B23K9/02—Seam welding; Backing means; Inserts
- B23K9/028—Seam welding; Backing means; Inserts for curved planar seams
- B23K9/0288—Seam welding; Backing means; Inserts for curved planar seams for welding of tubes to tube plates
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K37/00—Auxiliary devices or processes, not specially adapted to a procedure covered by only one of the preceding main groups
- B23K37/02—Carriages for supporting the welding or cutting element
- B23K37/0264—Carriages for supporting the welding or cutting element magnetically attached to the workpiece
Definitions
- the present disclosure relates to a welding tool and to a method of using a welding tool.
- Welding torches are used to weld together metal objects.
- welds When many welds are required, for example for large construction projects, it can be laborious and time consuming for a human to repetitively produce many welds of a consistently high quality.
- requiring a human to produce a large number of such welds may lead to mobility, health, and/or ergonomics issues.
- the ability to produce multiple welds of a consistently high quality has been automated to some extent, such automated devices are typically not easily portable, and the objects to be welded generally have to be brought to the welding device for welding.
- a welding tool comprising: a support structure; a welding torch coupled to the support structure and configured to rotate relative to the support structure about a welding axis; and a locating device coupled to the support structure and movable between a retracted position and an extended position in which the locating device extends toward the welding axis, wherein the locating device comprises a recess at an end thereof and is configured such that, when an object to be welded is positioned at least partially within the recess of the locating device in the extended position, the welding axis passes through the object to be welded.
- the welding tool may be operated by a labourer (a qualified welder is ideally not required).
- the welding torch may be rotatably coupled to the support structure so as to rotate about the welding axis.
- the recess may be sized and/or shaped such that, when the object to be welded is positioned at least partially within the recess of the locating device in the extended position, the welding axis passes through the object to be welded.
- the recess may comprise a triangular shape.
- the locating device may be configured to rotate between the retracted position and the extended position.
- the locating device may be further configured to translate toward and away from the welding axis.
- the support structure may comprise one or more magnets for securing the welding tool to a work surface.
- the magnets may be provided in a base of the support structure.
- An angle of the welding torch relative to the welding axis may be adjustable.
- the support structure may comprise a base with a central aperture formed therein. In the extended position, the locating device may extend into the central aperture.
- the locating device may comprise a first portion coupled to the support structure and a second portion extending at an angle (e.g. a non-horizontal angle) to the first portion, and the recess may be formed within the second portion.
- the second portion may extend through the central aperture.
- the second portion may comprise a first member extending at an angle (e.g. a non-horizontal angle) to the first portion and a second member extending at an angle (e.g. a non-horizontal angle) to the first member.
- the recess may be formed within the second member. When the locating device is in the extended position, the second member may extend perpendicular to the welding axis.
- the object to be welded may comprise an anchor rod.
- the object to be welded may comprise any other suitable object, such as a circular plate.
- the welding tool may further comprise a controller configured to implement a method comprising: activating the welding torch; rotating the welding tool about the welding axis; and deactivating the welding torch.
- the controller may be communicatively coupled to the welding torch so as to cause the welding torch to activate and deactivate.
- the controller may furthermore control one or more motors or similar devices for causing the welding tool to rotate about the welding axis.
- the motors may cause a rotatable element of the support structure, to which the welding tool is coupled, to rotate relative to the support structure.
- the welding tool may be portable by a user. For example, it may be possible to relocate the welding tool manually, without the need for a hoist or lift.
- a welding tool comprising: a support structure; a welding torch coupled to the support structure and configured to rotate relative to the support structure about a welding axis; and a locating device coupled to the support structure and rotatable between a retracted position and an extended position in which the locating device extends toward the welding axis, wherein the locating device is configured such that, when an object to be welded is positioned in contact with an end of the locating device in the extended position, the welding axis passes through the object to be welded.
- the welding tool may comprise any of the features described above in connection with the first aspect of the disclosure.
- a system comprising: any of the above-described welding tools; and a controller configured to implement a method comprising: activating the welding torch; rotating the welding torch about the welding axis; and deactivating the welding torch.
- the method may further comprise moving the locating device from the extended position to the retracted position prior to activating the welding torch. Moving the locating device from the extended position to the retracted position may comprise translating the locating device away from the welding axis and rotating the locating device relative to the support structure.
- the method may further comprise moving the locating device from the retracted position to the extended position after deactivating the welding torch.
- the controller may control one or more motors or similar devices for causing the locating device to move between the retracted position to the extended position.
- the method may further comprise, prior to moving the locating device from the extended position to the retracted position, activating the one or more magnets comprised in the support structure.
- the method may further comprise, prior to activating the welding tool, rotating the welding tool about the welding axis.
- the controller may comprise: circuitry; or a processor communicative with memory having stored thereon computer program code configured when executed by the processor to cause the processor to implement the method.
- the system may comprise any of the features described above in connection with the first aspect of the disclosure.
- a method of welding comprising: providing any of the above-described welding tools; when the locating device is in the extended position, positioning the object to be welded in contact with the end of the locating device such that the welding axis passes through the object to be welded; moving the locating device to the retracted position; activating the welding torch; and rotating the welding torch about the welding axis so as to weld the object to be welded.
- FIG. 1 is a schematic diagram of a welding tool according to embodiments of the disclosure
- FIG. 2 is a view of an underside of the welding tool of FIG. 1 ;
- FIG. 3 shows a centering leg in an extended position, according to embodiments of the disclosure
- FIG. 4 shows the centering leg of FIG. 3 in a retracted position
- FIG. 5 shows a welding tool according to embodiments of the disclosure
- FIG. 6 is a flow diagram of a method of using a welding tool, according to embodiments of the disclosure.
- FIG. 7 shows schematic diagrams of different welds
- FIG. 8 shows an 8 mm fillet weld
- FIG. 9 shows a penetration profile of a weld
- FIG. 10 shows a result of a pull test.
- the present disclosure seeks to provide an improved welding tool and method of using such a welding tool. While various embodiments of the disclosure are described below, the disclosure is not limited to these embodiments, and variations of these embodiments may well fall within the scope of the disclosure which is to be limited only by the appended claims.
- Coupled can have several different meanings depending on the context in which these terms are used.
- the terms coupled, coupling, or connected can have a mechanical or electrical connotation.
- the terms coupled, coupling, or connected can indicate that two elements or devices are directly connected to one another or connected to one another through one or more intermediate elements or devices via an electrical element, electrical signal or a mechanical element depending on the particular context.
- the term “and/or” herein when used in association with a list of items means any one or more of the items comprising that list.
- a reference to “about” or “approximately” a number or to being “substantially” equal to a number means being within +/ ⁇ 10% of that number.
- the welding tool includes a welding torch configured to rotate about a welding axis, and a locating device (which may also be referred to as a centering leg) used to position an object to be welded (which according to embodiments may be an anchor rod) on the welding axis.
- the welding tool may incorporate multiple bracing pillars on rubber feet to provide a stable structure that has sufficient weight to remain in place throughout rotation of the welding torch.
- the centering leg includes a tailored recess or notch for properly aligning the anchor rod on the welding axis, thereby ensuring that the welding torch has a consistent line into the joint.
- the welding torch may be provided at an adjustable angle and a pre-set elevation relative to the base of the support structure, and may be configured to rotate around the centre of the structure.
- the weld may be performed in one direction of rotation and then in the other, thus ensuring that no kinks arise in the welding cable that would result in wire feeding issues.
- welding tool 10 comprises a tool support structure 12 including a base 14 , an upper support 16 , and multiple bracing pillars 18 extending from base 14 to upper support 16 .
- a circular handle 20 extends upwardly from upper support 16 .
- Welding tool 10 further includes a welding torch 22 rotatably coupled to upper support 16 by means of a rotator 24 and a torch support 26 .
- Rotator 24 and torch support 26 are shown in more detail in FIG. 2 which shows an underside of welding tool 10 .
- Rotator 24 is configured to allow welding torch 22 to rotate through 360 degrees about a welding axis W passing through the centre of welding tool 10 .
- Welding torch 22 comprises a torch body 28 joined to a welding cable 30 extending through a central aperture 32 formed within upper support 16 .
- the underside of bracing pillars 18 include rubber feet 34 , and magnets 36 are provided within base 14 .
- Welding tool 10 further includes a locating device, or centering leg 38 , shown in more detail in FIGS. 3 and 4 .
- Centering leg 38 is rotatably coupled to tool support structure 12 .
- welding tool 10 includes an actuable arm 40 configured to move centering leg 38 between an extended position and an upright, retracted position. The extended position of centering leg 38 can be seen in more detail in FIG. 3 , and the retracted positon of centering leg 38 can be seen in more detail in FIG. 4 .
- Centering leg 38 includes a first portion 42 rotatably attached to base 14 , and a second portion 44 rotatable relative to first portion 42 .
- Second portion 44 includes an angled extension 46 extending away from first portion 42 at a downward angle thereto, and an end portion 48 extending away from angled extension 46 at an angle thereto. End portion 48 is substantially parallel to first portion 42 . In the extended position, centering leg 38 extends through a central aperture 50 formed within base 14 .
- End portion 48 of centering leg 38 includes a recess or notch 52 formed therein.
- Notch 52 comprises generally a triangular shape at the end of centering leg 38 , although the skilled person will recognize that the disclosure extends to recesses having other suitable shapes.
- Notch 52 is sized such that, when an anchor rod 54 is positioned within notch 52 and in contact with the sides of notch 52 , welding axis W passes through the centre of anchor rod 54 .
- welding tool 10 includes a controller 56 for controlling operation of welding tool 10 .
- controller 56 includes circuitry configured to enable welding tool 10 to perform various actions.
- controller 56 may activate magnets 36 in order for welding tool 10 to be secured to a metallic work surface 58 ( FIGS. 3 and 4 ).
- Controller 56 may additionally control the extension and retraction of centering leg 38 , as well as the rotation of rotator 24 relative to upper support 16 .
- controller 56 may control activation and deactivation of welding torch 22 .
- controller 56 may comprise a processor communicative with memory having stored thereon computer program code configured, when executed by the processor, to cause the processor to implement one or more of the above functions. Further still, in some embodiments controller 56 may be provided independently of welding tool 10 , and controller 56 may be configured for example to control welding tool 10 remotely.
- FIG. 6 a method 60 of performing welding, using welding tool 10 .
- Centering leg 38 is initially in the extended position.
- welding tool 10 is positioned over the anchor rod 54 to be welded.
- anchor rod 54 is located within notch 52 of centering leg 38 and is positioned in contact with the sides of notch 52 .
- a user uses controller 56 to activate magnets 36 .
- magnets 36 Once magnets 36 are activated, at block 63 , the user may then push downwardly on welding tool 10 , using handle 20 .
- rubber feet 34 compress and magnets 36 approach metal work surface 58 until welding tool 10 is securely engaged to work surface 58 .
- Controller 56 is then used to initiate a welding sequence, as follows.
- controller actuates arm 40 to rotate centering leg 38 into the retracted position.
- controller 56 activates welding torch 22 .
- controller 56 rotates welding torch 22 to form the joint between anchor rod 54 and work surface 58 .
- welding torch 22 is rotated through an angle of greater than 360 degrees (in some embodiments, 368 degrees). This enables the start of the weld to be filled.
- controller 56 deactivates welding torch 22. Rotator 24 may then rotate welding torch 22 back to its original position, to ensure that no kinks develop in welding cable 30 .
- controller 56 actuates arm 40 to rotate centering leg 38 into the extended position, for subsequent welding.
- a user may use controller 56 to rotate welding torch 22 a predetermined amount, for example prior to welding. This allows a user to determine the point at which welding torch 22 begins welding.
- Three separate specimens were originally considered for three test types (a total of nine tests) using a 3 ⁇ 8′′ all-around fillet weld (Type A), a 5/16′′ fillet weld (Type B) and a 1 ⁇ 4′′ fillet weld (Type C) for the anchor rod to plate connection.
- a heavy, 2′′ plate was used to simulate the concrete-filled core backing the shell plate.
- Type C (1 ⁇ 4′′ weld) had the weld fracture and rod pull through the plate. This was a result of both minimum weld material and heat input.
- the 6 mm (1 ⁇ 4′′) fillet weld was of adequate size to satisfy the structural requirements of the anchor rod fillet weld, but given the travel speed during welding necessary to generate the smaller fillet weld size, it is unrealistic to produce consistent penetration profiles at these speeds.
- the 8 mm ( 5/16′′) fillet option provides an improved compromise between welding efficiency and a consistent weld that meets the structural requirements.
- a manually welded 8 mm fillet weld underwent mechanical testing, showing that the failure upon tensile testing occurs within the anchor rod, exhibiting a traditional necking to failure mechanism.
- An example of the 8 mm fillet weld produced by the welding tool can be seen in FIG. 8 .
- FIG. 8 shows a representative example of a weld produced using the automated welding tool.
- the use of the 1.6 mm electrode allowed for increased welding efficiency and increased the current level as compared to the 1.3 mm wire which in turn led to a deeper penetration profile.
- the deeper penetration profile can be seen in FIG. 9 . It was observed that for welds with insufficient penetration profiles, the failure mode of the anchor rod specimens still occurred within the rod, but occurred at the top of the anchor rod, in close proximity to the weld.
- the automated welding tool has been shown to provide a satisfactory weldment, particularly with the MCAW process.
- the use of the 1.6 mm consumable allowed for a significant ( ⁇ 50%) reduction in the welding time for one anchor rod.
- the deep penetration profile and consistent outer weld profile indicate that this process can effectively provide reliable results.
Landscapes
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Mechanical Engineering (AREA)
- Plasma & Fusion (AREA)
- Optics & Photonics (AREA)
- Butt Welding And Welding Of Specific Article (AREA)
Abstract
Description
- The present disclosure relates to a welding tool and to a method of using a welding tool.
- Welding torches are used to weld together metal objects. When many welds are required, for example for large construction projects, it can be laborious and time consuming for a human to repetitively produce many welds of a consistently high quality. In addition, requiring a human to produce a large number of such welds may lead to mobility, health, and/or ergonomics issues. Although the ability to produce multiple welds of a consistently high quality has been automated to some extent, such automated devices are typically not easily portable, and the objects to be welded generally have to be brought to the welding device for welding.
- According to a first aspect of the disclosure, there is provided a welding tool comprising: a support structure; a welding torch coupled to the support structure and configured to rotate relative to the support structure about a welding axis; and a locating device coupled to the support structure and movable between a retracted position and an extended position in which the locating device extends toward the welding axis, wherein the locating device comprises a recess at an end thereof and is configured such that, when an object to be welded is positioned at least partially within the recess of the locating device in the extended position, the welding axis passes through the object to be welded.
- Thus, with the welding tool described above, multiple welds surrounding anchor rods (or other suitable objects to be welded) may be rapidly and accurately produced. The welding tool may be operated by a labourer (a qualified welder is ideally not required).
- The welding torch may be rotatably coupled to the support structure so as to rotate about the welding axis.
- The recess may be sized and/or shaped such that, when the object to be welded is positioned at least partially within the recess of the locating device in the extended position, the welding axis passes through the object to be welded.
- The recess may comprise a triangular shape.
- The locating device may be configured to rotate between the retracted position and the extended position. The locating device may be further configured to translate toward and away from the welding axis.
- The support structure may comprise one or more magnets for securing the welding tool to a work surface. The magnets may be provided in a base of the support structure.
- An angle of the welding torch relative to the welding axis may be adjustable.
- The support structure may comprise a base with a central aperture formed therein. In the extended position, the locating device may extend into the central aperture.
- The locating device may comprise a first portion coupled to the support structure and a second portion extending at an angle (e.g. a non-horizontal angle) to the first portion, and the recess may be formed within the second portion. When the locating device is in the extended position, the second portion may extend through the central aperture.
- The second portion may comprise a first member extending at an angle (e.g. a non-horizontal angle) to the first portion and a second member extending at an angle (e.g. a non-horizontal angle) to the first member. The recess may be formed within the second member. When the locating device is in the extended position, the second member may extend perpendicular to the welding axis.
- The object to be welded may comprise an anchor rod. In some embodiments, the object to be welded may comprise any other suitable object, such as a circular plate.
- The welding tool may further comprise a controller configured to implement a method comprising: activating the welding torch; rotating the welding tool about the welding axis; and deactivating the welding torch. For example, the controller may be communicatively coupled to the welding torch so as to cause the welding torch to activate and deactivate. The controller may furthermore control one or more motors or similar devices for causing the welding tool to rotate about the welding axis. For example, the motors may cause a rotatable element of the support structure, to which the welding tool is coupled, to rotate relative to the support structure.
- The welding tool may be portable by a user. For example, it may be possible to relocate the welding tool manually, without the need for a hoist or lift.
- According to further aspect of the disclosure, there is provided a welding tool comprising: a support structure; a welding torch coupled to the support structure and configured to rotate relative to the support structure about a welding axis; and a locating device coupled to the support structure and rotatable between a retracted position and an extended position in which the locating device extends toward the welding axis, wherein the locating device is configured such that, when an object to be welded is positioned in contact with an end of the locating device in the extended position, the welding axis passes through the object to be welded.
- The welding tool may comprise any of the features described above in connection with the first aspect of the disclosure.
- According to further aspect of the disclosure, there is provided a system comprising: any of the above-described welding tools; and a controller configured to implement a method comprising: activating the welding torch; rotating the welding torch about the welding axis; and deactivating the welding torch. The method may further comprise moving the locating device from the extended position to the retracted position prior to activating the welding torch. Moving the locating device from the extended position to the retracted position may comprise translating the locating device away from the welding axis and rotating the locating device relative to the support structure.
- The method may further comprise moving the locating device from the retracted position to the extended position after deactivating the welding torch. For example, the controller may control one or more motors or similar devices for causing the locating device to move between the retracted position to the extended position.
- The method may further comprise, prior to moving the locating device from the extended position to the retracted position, activating the one or more magnets comprised in the support structure.
- The method may further comprise, prior to activating the welding tool, rotating the welding tool about the welding axis.
- The controller may comprise: circuitry; or a processor communicative with memory having stored thereon computer program code configured when executed by the processor to cause the processor to implement the method.
- The system may comprise any of the features described above in connection with the first aspect of the disclosure.
- In a further aspect of the disclosure, there is provided a method of welding, comprising: providing any of the above-described welding tools; when the locating device is in the extended position, positioning the object to be welded in contact with the end of the locating device such that the welding axis passes through the object to be welded; moving the locating device to the retracted position; activating the welding torch; and rotating the welding torch about the welding axis so as to weld the object to be welded.
- Embodiments of the disclosure will now be described in conjunction with the accompanying drawings of which:
-
FIG. 1 is a schematic diagram of a welding tool according to embodiments of the disclosure; -
FIG. 2 is a view of an underside of the welding tool ofFIG. 1 ; -
FIG. 3 shows a centering leg in an extended position, according to embodiments of the disclosure; -
FIG. 4 shows the centering leg ofFIG. 3 in a retracted position; -
FIG. 5 shows a welding tool according to embodiments of the disclosure; -
FIG. 6 is a flow diagram of a method of using a welding tool, according to embodiments of the disclosure; -
FIG. 7 shows schematic diagrams of different welds; -
FIG. 8 shows an 8 mm fillet weld; -
FIG. 9 shows a penetration profile of a weld; and -
FIG. 10 shows a result of a pull test. - The present disclosure seeks to provide an improved welding tool and method of using such a welding tool. While various embodiments of the disclosure are described below, the disclosure is not limited to these embodiments, and variations of these embodiments may well fall within the scope of the disclosure which is to be limited only by the appended claims.
- The word “a” or “an” when used in conjunction with the term “comprising” or “including” in the claims and/or the specification may mean “one”, but it is also consistent with the meaning of “one or more”, “at least one”, and “one or more than one” unless the content clearly dictates otherwise. Similarly, the word “another” may mean at least a second or more unless the content clearly dictates otherwise.
- The terms “coupled”, “coupling” or “connected” as used herein can have several different meanings depending on the context in which these terms are used. For example, the terms coupled, coupling, or connected can have a mechanical or electrical connotation. For example, as used herein, the terms coupled, coupling, or connected can indicate that two elements or devices are directly connected to one another or connected to one another through one or more intermediate elements or devices via an electrical element, electrical signal or a mechanical element depending on the particular context. The term “and/or” herein when used in association with a list of items means any one or more of the items comprising that list.
- As used herein, a reference to “about” or “approximately” a number or to being “substantially” equal to a number means being within +/−10% of that number.
- Generally, according to embodiments of the disclosure, there is described an automated welding tool. The welding tool includes a welding torch configured to rotate about a welding axis, and a locating device (which may also be referred to as a centering leg) used to position an object to be welded (which according to embodiments may be an anchor rod) on the welding axis. The welding tool may incorporate multiple bracing pillars on rubber feet to provide a stable structure that has sufficient weight to remain in place throughout rotation of the welding torch. At one end thereof, the centering leg includes a tailored recess or notch for properly aligning the anchor rod on the welding axis, thereby ensuring that the welding torch has a consistent line into the joint.
- The welding torch may be provided at an adjustable angle and a pre-set elevation relative to the base of the support structure, and may be configured to rotate around the centre of the structure. The weld may be performed in one direction of rotation and then in the other, thus ensuring that no kinks arise in the welding cable that would result in wire feeding issues. After placement of the anchor rod into the recess of the centering leg, but prior to the welding sequence, the centering leg automatically retracts into an upright position to allow free rotation of the welding torch.
- The figures will now be described in more detail. Turning to
FIG. 1 , and according to embodiments of the disclosure,welding tool 10 comprises atool support structure 12 including abase 14, anupper support 16, and multiple bracingpillars 18 extending frombase 14 toupper support 16. Acircular handle 20 extends upwardly fromupper support 16.Welding tool 10 further includes awelding torch 22 rotatably coupled toupper support 16 by means of arotator 24 and atorch support 26.Rotator 24 andtorch support 26 are shown in more detail inFIG. 2 which shows an underside ofwelding tool 10.Rotator 24 is configured to allowwelding torch 22 to rotate through 360 degrees about a welding axis W passing through the centre ofwelding tool 10. Weldingtorch 22 comprises atorch body 28 joined to awelding cable 30 extending through acentral aperture 32 formed withinupper support 16. As can be seen inFIG. 2 , the underside of bracingpillars 18 includerubber feet 34, andmagnets 36 are provided withinbase 14. -
Welding tool 10 further includes a locating device, or centeringleg 38, shown in more detail inFIGS. 3 and 4 . Centeringleg 38 is rotatably coupled totool support structure 12. In particular,welding tool 10 includes anactuable arm 40 configured to move centeringleg 38 between an extended position and an upright, retracted position. The extended position of centeringleg 38 can be seen in more detail inFIG. 3 , and the retracted positon of centeringleg 38 can be seen in more detail inFIG. 4 . Centeringleg 38 includes afirst portion 42 rotatably attached tobase 14, and asecond portion 44 rotatable relative tofirst portion 42.Second portion 44 includes anangled extension 46 extending away fromfirst portion 42 at a downward angle thereto, and anend portion 48 extending away fromangled extension 46 at an angle thereto.End portion 48 is substantially parallel tofirst portion 42. In the extended position, centeringleg 38 extends through acentral aperture 50 formed withinbase 14. -
End portion 48 of centeringleg 38 includes a recess or notch 52 formed therein.Notch 52 comprises generally a triangular shape at the end of centeringleg 38, although the skilled person will recognize that the disclosure extends to recesses having other suitable shapes.Notch 52 is sized such that, when ananchor rod 54 is positioned withinnotch 52 and in contact with the sides ofnotch 52, welding axis W passes through the centre ofanchor rod 54. - Turning to
FIG. 5 which showswelding tool 10 according to embodiments of the disclosure,welding tool 10 includes acontroller 56 for controlling operation ofwelding tool 10. In particular,controller 56 includes circuitry configured to enablewelding tool 10 to perform various actions. For example,controller 56 may activatemagnets 36 in order for weldingtool 10 to be secured to a metallic work surface 58 (FIGS. 3 and 4 ).Controller 56 may additionally control the extension and retraction of centeringleg 38, as well as the rotation ofrotator 24 relative toupper support 16. Furthermore,controller 56 may control activation and deactivation ofwelding torch 22. In some embodiments, instead of or in addition to circuitry,controller 56 may comprise a processor communicative with memory having stored thereon computer program code configured, when executed by the processor, to cause the processor to implement one or more of the above functions. Further still, in someembodiments controller 56 may be provided independently ofwelding tool 10, andcontroller 56 may be configured for example to controlwelding tool 10 remotely. - Turning to
FIG. 6 , according to embodiments of the disclosure there is shown amethod 60 of performing welding, usingwelding tool 10. Centeringleg 38 is initially in the extended position. Atblock 61,welding tool 10 is positioned over theanchor rod 54 to be welded. In particular,anchor rod 54 is located withinnotch 52 of centeringleg 38 and is positioned in contact with the sides ofnotch 52. Atblock 62, a user usescontroller 56 to activatemagnets 36. Oncemagnets 36 are activated, atblock 63, the user may then push downwardly onwelding tool 10, usinghandle 20. Through the downward force applied towelding tool 10,rubber feet 34 compress andmagnets 36 approachmetal work surface 58 until weldingtool 10 is securely engaged towork surface 58.Controller 56 is then used to initiate a welding sequence, as follows. In particular, atblock 64, controller actuatesarm 40 to rotate centeringleg 38 into the retracted position. Atblock 65,controller 56 activateswelding torch 22. Atblock 66,controller 56 rotateswelding torch 22 to form the joint betweenanchor rod 54 andwork surface 58. In some embodiments,welding torch 22 is rotated through an angle of greater than 360 degrees (in some embodiments, 368 degrees). This enables the start of the weld to be filled. Atblock 67,controller 56 deactivateswelding torch 22.Rotator 24 may then rotatewelding torch 22 back to its original position, to ensure that no kinks develop inwelding cable 30. Atblock 68,controller 56 actuatesarm 40 to rotate centeringleg 38 into the extended position, for subsequent welding. - In some embodiments, a user may use
controller 56 to rotate welding torch 22 a predetermined amount, for example prior to welding. This allows a user to determine the point at whichwelding torch 22 begins welding. - Three different welds were initially considered, as set out below and as shown in
FIG. 7 . - 1. ⅜″ [10 mm] fillet weld (Type-A);
- 2. 5/16″ [8 mm] fillet weld (Type-B); and
- 3. ¼″ [6 mm] fillet weld (Type-C).
- Three separate specimens were originally considered for three test types (a total of nine tests) using a ⅜″ all-around fillet weld (Type A), a 5/16″ fillet weld (Type B) and a ¼″ fillet weld (Type C) for the anchor rod to plate connection. A heavy, 2″ plate was used to simulate the concrete-filled core backing the shell plate.
- Testing was run to failure, with all Type A and Type B specimens exhibiting yielding to fracture failure, while two of three Type C connections exhibited the same failure behavior. One Type C (¼″ weld) had the weld fracture and rod pull through the plate. This was a result of both minimum weld material and heat input. In summary, the 6 mm (¼″) fillet weld was of adequate size to satisfy the structural requirements of the anchor rod fillet weld, but given the travel speed during welding necessary to generate the smaller fillet weld size, it is unrealistic to produce consistent penetration profiles at these speeds.
- The 8 mm ( 5/16″) fillet option provides an improved compromise between welding efficiency and a consistent weld that meets the structural requirements. A manually welded 8 mm fillet weld underwent mechanical testing, showing that the failure upon tensile testing occurs within the anchor rod, exhibiting a traditional necking to failure mechanism. An example of the 8 mm fillet weld produced by the welding tool can be seen in
FIG. 8 . - Eight rod specimens welded using the automated welding tool were completed, four using metal-cored arc welding (MCAW) and another four using flux-cored arc welding (FCAW). The welding parameters and information regarding the consumables and welding processes for the test samples are shown in Table 1.
-
FIG. 8 shows a representative example of a weld produced using the automated welding tool. The use of the 1.6 mm electrode allowed for increased welding efficiency and increased the current level as compared to the 1.3 mm wire which in turn led to a deeper penetration profile. The deeper penetration profile can be seen inFIG. 9 . It was observed that for welds with insufficient penetration profiles, the failure mode of the anchor rod specimens still occurred within the rod, but occurred at the top of the anchor rod, in close proximity to the weld. -
TABLE 1 Welding parameters for test samples and process/consumable information. Sample Wire Feed Speed Voltage Travel Wire Dia. # m/min [ipm] V Setting Process Wire mm 1 7.62 [300] 32 25 MCAW E491C-6MJ-H4 1.6 E70C-6M-H4 2 7.62 [300] 32 25 MCAW E491C-6MJ-H4 1.6 E70C-6M-H4 3 7.62 [300] 32 25 MCAW E491C-6MJ-H4 1.6 E70C-6M-H4 4 7.62 [300] 32 25 MCAW E491C-6MJ-H4 1.6 E70C-6M- H4 5 8.89 [350] 28 18/19 FCAW E491T-9MJ-H8 1.6 E71T-9M-JH8 13 8.89 [350] 28 18/19 FCAW E491T-9MJ-H8 1.6 E71T-9M-JH8 15 8.89 [350] 28 18/19 FCAW E491T-9MJ-H8 1.6 E71T-9M- JH8 18 8.89 [350] 28 18/19 FCAW E491T-9MJ-H8 1.6 E71T-9M-JH8 - In four pull tests on the rod setup with both metal-cored arc welding MCAW and flux-cored arc welding FCAW, in all cases the failure occurred in the rod and the weld remained unaffected. These results clearly show that the 8 mm fillet weld generated with the automated welding tool is robust and consistent. An example of the pull test results is shown in
FIG. 10 . - Based on the results of tension testing and the consistency of the welds produced, the automated welding tool has been shown to provide a satisfactory weldment, particularly with the MCAW process. The use of the 1.6 mm consumable allowed for a significant (˜50%) reduction in the welding time for one anchor rod. The deep penetration profile and consistent outer weld profile indicate that this process can effectively provide reliable results.
- While the disclosure has been described in connection with specific embodiments, it is to be understood that the disclosure is not limited to these embodiments, and that alterations, modifications, and variations of these embodiments may be carried out by the skilled person without departing from the scope of the disclosure. It is furthermore contemplated that any part of any aspect or embodiment discussed in this specification can be implemented or combined with any part of any other aspect or embodiment discussed in this specification.
Claims (19)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US16/372,311 US10792749B1 (en) | 2019-04-01 | 2019-04-01 | Welding tool |
CA3038929A CA3038929A1 (en) | 2019-04-01 | 2019-04-02 | Welding tool and method of using a welding tool |
US17/007,791 US11638964B2 (en) | 2019-04-01 | 2020-08-31 | Welding tool and method of using a welding tool |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US16/372,311 US10792749B1 (en) | 2019-04-01 | 2019-04-01 | Welding tool |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US17/007,791 Continuation US11638964B2 (en) | 2019-04-01 | 2020-08-31 | Welding tool and method of using a welding tool |
Publications (2)
Publication Number | Publication Date |
---|---|
US20200306858A1 true US20200306858A1 (en) | 2020-10-01 |
US10792749B1 US10792749B1 (en) | 2020-10-06 |
Family
ID=72606865
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US16/372,311 Active US10792749B1 (en) | 2019-04-01 | 2019-04-01 | Welding tool |
US17/007,791 Active 2040-01-24 US11638964B2 (en) | 2019-04-01 | 2020-08-31 | Welding tool and method of using a welding tool |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US17/007,791 Active 2040-01-24 US11638964B2 (en) | 2019-04-01 | 2020-08-31 | Welding tool and method of using a welding tool |
Country Status (2)
Country | Link |
---|---|
US (2) | US10792749B1 (en) |
CA (1) | CA3038929A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN115781133A (en) * | 2023-01-06 | 2023-03-14 | 湖北恒泰电线电缆有限公司 | Automatic steel band welding machine to material |
CN117086536A (en) * | 2023-10-20 | 2023-11-21 | 南通宝恒工贸有限公司 | Transformer conducting rod welding device for extra-high voltage power transmission |
Family Cites Families (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2930883A (en) | 1957-12-23 | 1960-03-29 | Ckd Ceska Lipa Narodni Podnik | Apparatus for automatic arc-welding circular seams |
US3064120A (en) | 1960-07-08 | 1962-11-13 | Westinghouse Electric Corp | Welding apparatus |
DE1142977B (en) | 1961-05-19 | 1963-01-31 | Deggendorfer Werft Eisenbau | Device for automatic arc welding of circular ring seams, in particular for welding pipes into pipe bases |
US3345494A (en) | 1964-04-07 | 1967-10-03 | Foster Wheeler Corp | Rotatable arc welding torch |
US3594534A (en) | 1969-03-21 | 1971-07-20 | Compak O Matic Inc | Welding apparatus |
SE468038B (en) | 1991-03-07 | 1992-10-26 | Esab Ab | CENTERING CENTER FOR CENTERING OF A PIPE WELDING APPARATUS RELATIVELY A PIPE TO WELD TO A GABLE PLATE |
DE4312439C2 (en) * | 1993-04-16 | 1995-02-09 | Ilch Hartmut Dipl Ing Fh | Device and method for welding a weld-on part and a base part |
JP3906404B2 (en) * | 2001-04-14 | 2007-04-18 | 好高 青山 | Parts welding equipment |
KR101741457B1 (en) | 2015-12-04 | 2017-05-30 | 삼성중공업 주식회사 | Welding apparatus |
-
2019
- 2019-04-01 US US16/372,311 patent/US10792749B1/en active Active
- 2019-04-02 CA CA3038929A patent/CA3038929A1/en active Pending
-
2020
- 2020-08-31 US US17/007,791 patent/US11638964B2/en active Active
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN115781133A (en) * | 2023-01-06 | 2023-03-14 | 湖北恒泰电线电缆有限公司 | Automatic steel band welding machine to material |
CN117086536A (en) * | 2023-10-20 | 2023-11-21 | 南通宝恒工贸有限公司 | Transformer conducting rod welding device for extra-high voltage power transmission |
Also Published As
Publication number | Publication date |
---|---|
US11638964B2 (en) | 2023-05-02 |
US10792749B1 (en) | 2020-10-06 |
US20200398361A1 (en) | 2020-12-24 |
CA3038929A1 (en) | 2020-10-01 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US11638964B2 (en) | Welding tool and method of using a welding tool | |
JP6505715B2 (en) | TIG welding system | |
CN106270981B (en) | The stud welding gun continuously welded can be achieved | |
CN206382749U (en) | It can adjust mobile welding support | |
JP2017020569A (en) | Blank manufacturing system and method for bimetal screw | |
KR102307068B1 (en) | Automatic welding device with easy angle adjustment | |
JPH11170064A (en) | Welding equipment of nut | |
CN204248312U (en) | A kind of auto panel two point positioning fixture | |
CN204353681U (en) | Auto panel fixture | |
CN207119884U (en) | A kind of system that tie pole is welded using arc pulling type arc stud welding | |
CN207930146U (en) | A kind of damper clamp support projection welding welding tooling | |
CN204565388U (en) | Simple circular seam welder | |
JP2010082674A (en) | Robot arc welding system and welding operation method of the same | |
CN206747749U (en) | A kind of pneumatic brazing jig of fast positioning clamping multi-group workpiece | |
JP2007260771A (en) | Automatic spot welding method | |
CN206326304U (en) | One kind turns button weld jig | |
CN206326233U (en) | A kind of stitch welding machine | |
CN204248308U (en) | A kind of fixture for auto panel | |
CN209919228U (en) | All-dimensional clamping rotatable deflection welding machine | |
CN213033988U (en) | Clamp device for welding teaching | |
JP7339147B2 (en) | arc welding robot system | |
CN206898685U (en) | For the assembling-welding fixtures being installed to kuppe reinforcing plate on white body | |
CN219336361U (en) | Wire ultrasonic welding device | |
CN205629661U (en) | Laser welding device of sensor | |
CN207431483U (en) | Welding head |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
FEPP | Fee payment procedure |
Free format text: ENTITY STATUS SET TO UNDISCOUNTED (ORIGINAL EVENT CODE: BIG.); ENTITY STATUS OF PATENT OWNER: LARGE ENTITY |
|
AS | Assignment |
Owner name: SUPREME GROUP LP, CANADA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:CUPIDO, WILFRED JEROME;LEDER, JOHN;SIGNING DATES FROM 20200619 TO 20200715;REEL/FRAME:053275/0623 |
|
STCF | Information on status: patent grant |
Free format text: PATENTED CASE |
|
MAFP | Maintenance fee payment |
Free format text: PAYMENT OF MAINTENANCE FEE, 4TH YEAR, LARGE ENTITY (ORIGINAL EVENT CODE: M1551); ENTITY STATUS OF PATENT OWNER: LARGE ENTITY Year of fee payment: 4 |