Orbital welding apparatus

Patent metadata

Field	Value
Publication number	US-12083632-B2
Application number	US-202117308538-A
Country	US
Kind code	B2
Filing date	May 5, 2021
Priority date	May 7, 2020
Publication date	Sep 10, 2024
Grant date	Sep 10, 2024

Abstract

The disclosure relates to an orbital welding head for an orbital welding apparatus for connecting by means of a cable to a welding current source in a welding current source housing, said current source being equipped with a base controller. The orbital welding head has a tube mount and a welding electrode holder rotatably supported opposite the tube mount for mounting a welding electrode, wherein the orbital welding apparatus has a motor, which is configured in order to drive the welding electrode holder and thus rotate it opposite the tube mount, wherein the orbital welding head has a chamber for inert gas, which is configured in order to surround the welding electrode of the orbital welding head during a welding process and to essentially terminate it outwardly. The orbital welding head has an electronic circuit, which has a memory arranged in the orbital welding head. The electronic circuit is configured in order to store one or more electrode load values of the welding electrode. The electronic circuit of the orbital welding head and/or the base controller is configured such that a maintenance state value of the welding electrode is determined on the basis of the electrode load values, said state being a measure of wear on the welding electrode.

First claim

What is claimed is:

1. An orbital welding head for an orbital welding apparatus for connecting by means of a cable to a welding current source in a welding current source housing, said current source being equipped with a base controller, comprising:
a tube mount and a welding electrode holder rotatably supported opposite the tube mount for mounting a welding electrode;
a motor, which is configured in order to drive the welding electrode holder and thus rotate the welding electrode holder opposite the tube mount;
an electronic circuit comprising a memory, which is arranged in the orbital welding head, wherein the electronic circuit is configured to:
store one or more electrode load values of the welding electrode, and the electronic circuit of at least one of the orbital welding head or the base controller is configured such that a maintenance state value of the welding electrode is determined on the basis of the electrode load values, said state being a measure of the wear on the welding electrode based on a number of welding operations, an arc energy, or time; and
monitor the curve of at least one of the determined electrode load values or maintenance state values; and
identify unacceptable wear on the welding electrode based on at least one of:
identifying that the electrode load values are outside of a range set by a predetermined deviation from a location on a predetermined curve, the location on the predetermined curve being based on the number of welding operations, the arc energy, or the time; or
identifying overshooting or undershooting of the at least one of the determined electrode load value or the maintenance state value based on a location on a predetermined curve, the location on the predetermined curve being based on the number of welding operations, the arc energy, or the time.

2. The orbital welding head according to claim 1 , wherein the electronic circuit is configured such that one or more electrode load values are initially stored as reference values, the curve is set based on the reference values, and the wear on the welding electrode is determined by comparing one or more further electrode load values to the curve.

3. The orbital welding head according to claim 1 , further comprising a monitoring module configured to:
automatically monitor the deviation from at least one of the predetermined curve or the undershooting or overshooting and;
when unacceptable wear is detected, generate a warning, wherein the monitoring module is configured such that a deviation threshold value for the at least one of the predetermined deviation or the threshold for overshooting or undershooting this threshold value is manually settable and changeable.

4. The orbital welding head according to claim 1 , wherein the one or more electrode load values have one or more of the following parameters:
measured voltage at the welding electrode,
measured resistance on the electrode,
all electrical work performed at the welding electrode,
total electrical charge flowing through the welding electrode,
all electrical active energy performed by the welding electrode,
maximum current per welding operation,
electrical charge per welding operation,
electrical work or active energy per welding operation,
total operating time.

5. The orbital welding head according to claim 1 , further comprising a resetting device for resetting the one or more electrode load values when replacing a welding electrode.

6. The orbital welding head according to claim 1 , further comprising an output device on the orbital welding head to indicate a maintenance state of the welding electrode located in the orbital welding head.

7. The orbital welding head according to claim 1 , wherein the orbital welding head comprises a communication device for communicating with the base controller via a bidirectional digital data link.

8. An orbital welding apparatus having a welding current source in a welding current source housing, said current source being equipped with a base controller, and an orbital welding head according to claim 1 .

9. The orbital welding apparatus according to claim 8 , wherein the base controller comprises a base communication device for communicating via the data link with the communication device of the orbital welding head, wherein the base controller is configured in order to read one or more electrode load values, which are present on at least one of the base controller or at the welding current source, or are measured at the welding current source by means of one or more sensors, and the base controller is configured to pass the one or more electrode load values on to the orbital welding head.

10. The orbital welding apparatus according to claim 8 , wherein the base controller, when executing a welding program, considers at least one of A) the maintenance state of the welding electrode as defined by the electrode load value(s) stored in the orbital welding head, wherein a respective welding program is adjusted to the maintenance state of the welding electrode, or B) when selecting one of a plurality of welding programs, considers the maintenance state of the welding electrode.

11. A method for operating an orbital welding apparatus, comprising:
passing current from a welding current source by means of a cable to an orbital welding head;
driving a welding electrode holder on the orbital welding head via a motor, wherein the welding electrode holder is rotated opposite a tube mount of the orbital welding head;
surrounding a welding electrode of the orbital welding head with inert gas during a welding process;
storing one or more electrode load values of a welding electrode are stored in a memory via an electronic circuit which is arranged in the orbital welding head; and
storing, in a memory arranged in the orbital welding head, one or more electrode load values of a welding electrode and determining wear on the welding electrode by at least one of:
comparing that the electrode load values to a range set by a predetermined deviation from a location on a predetermined curve, the location on the predetermined curve being based on a number of welding operations, an arc energy, or a time; or
identifying whether the determined electrode load value or the maintenance state value has overshot or undershot at least one of the determined electrode load value or the maintenance state value based on a location on a predetermined curve, the location on the predetermined curve being based on the number of welding operations, the arc energy, or the time.

Assignees

• Illinois Tool Works

Inventors

• Tamm Markus
• Foh Marcel

Classifications

• B23K9/0956

  using sensing means, e.g. optical · CPC title

• B23K9/0953

  using computing means · CPC title

• B23K9/167

  and of a non-consumable electrode · CPC title

• B23K9/095

  Monitoring or automatic control of welding parameters · CPC title

• B23K9/0286 Primary

  with an electrode moving around the fixed tube during the welding operation · CPC title