SBIR-STTR Award

Orbital pipe welding systems can function like skilled welders, to certain extent, who can move the torch very smoothly/evenly. However, their adjustment of welding parameters is not a true emulation of skilled welders who observe the weld pool and adjust welding parameters based on the observation of the weld pool rather than simply the location around the clock. This SBIR project aims at the development of an adaptive intelligent control technology which can adaptively adjust welding parameters based on an observation of the weld pool surface like a skilled welder but does not require the torch be moved smoothly/evenly. One of the major innovations associated with the proposed technology is a so-called "torch sensor" which can measure the depth of the weld pool surface like a skilled welder. This sensor torch can be carried by a human welder and can last "forever" as a regular welding torch does. Another major innovation is the so-called quasi-keyhole technology which achieves the desired weld joint penetration every cycle so that the response of the control system to fluctuations/variations in welder's operations and joint preparation etc. is truly real-time. Phase I project is designed to verify the feasibility of the proposed technology.

Keywords:
Sensor, Control, Welding, Skills, Productivity, Welding Speed, Worker Health

Orbital pipe welding systems are not true emulation of skilled welders who adjust welding parameters based on observation on the weld pool. This SBIR Phase II project aims at the development of commercial prototype systems which can adaptively adjust welding parameters based on an observation on the weld pool surface like a skilled welder but does not require the torch to be moved smoothly/evenly. One of the major innovations associated with this technology is a so-called "torch sensor" which can ¡°observe¡± the weld pool surface to measure its depth. In addition, this sensor is adaptive in response to possible fluctuations/variations in welder's operations. Another major innovation is the control strategy used, which reduces the current to a lower level each cycle once the desired weld pool surface depth is achieved rather than trying to maintain the depth at the desired level. Phase II base and option I projects are designed to develop the first commercial prototype for manual welding of pipes by relatively inexperienced welders. If the option II project is awarded, another commercial prototype will be developed to integrate the technology into an orbital system for automated orbital pipe welding. Phase III aims at their adoption to DDX program.

Keywords:
Welding, Pipe, Manufacturing, Sensor, Control, System, Labor Skill