Objective A computer-based solution has been developed for a range of fully automated orbital welding applications, based upon a modular VME-bus control rack. The rack provides the control for all motion axes for the orbital heads (stepper and servo motors for rotation, weave, stand-off and wire-feeding), calibrates gas flow control valves, and remotely programmes and controls an independent welding power source in real-time. Serial links are used to interface the control computer with the control rack, and the control rack with the power source CPU. All the welding and orbital motion parameters are configured and stored in a database on the control computer. The derived core modular system (comprising the VME-rack and power source) was used to control a range of orbital heads for various multi-purpose applications: - autogenous small-bore TIG for ultra-high purity tubing (SS316L), - pulsed plasma keyhole and MIG welding of medium diameter steam generating plant pipelines (SA 106 Gr C and also SA 335 P22), and - large diameter lay barge pipes (carbon steel API 5L X65) and duplex stainless steel SAF 2205). Significant development work was also undertaken on optimised procedures for the UHP tubing, with respect to minimising the surface roughness of the inner weld bead for improved UHP commissioning time for example. Real-time penetration monitoring of the process was demonstrated for small bore tubes. The system employs a dedicated signal conditioning unit, A/D card, 486-processor and software which utilises weld pool oscillations generated by current pulses and detected in the arc voltage. Plasma keyhole opening and closure parameter development for the completion of a full orbital root pass was also significantly improved by programmable simultaneous control of gas and current sloping parameters for both the power generating and lay barge pipe applications.The project concerns the development of an innovative modular process package for automatic orbital welding of pipe-lines.A computer controlled multiprocess power source will be used with a variety of welding processes; varying from pulsed keyhole plasma to flux cored wire welding. Adaptive control techniques will be implemented to ensure that the required joint quality can be achieved under normal operating conditions. It will be demonstrated that a cost-effective equipment/process package can be developed and the techniques involved will be proved on applications as diverse as lay barge welding of oil pipelines at sea to the site welding of ultra-clean inert gas distribution systems. Fields of science natural sciencescomputer and information sciencessoftwarenatural sciencescomputer and information sciencesdatabasesengineering and technologyelectrical engineering, electronic engineering, information engineeringelectronic engineeringcomputer hardwarecomputer processorsnatural sciencesphysical sciencesclassical mechanicsfluid mechanicsfluid dynamics Programme(s) FP3-BRITE/EURAM 2 - Specific programme (EEC) of research and technological development in the field of industrial and materials technologies, 1990-1994 Topic(s) 2.2.1 - Tools, techniques and systems for high quality manufacturing Call for proposal Data not available Funding Scheme CSC - Cost-sharing contracts Coordinator CRANFIELD UNIVERSITY Address Road wharley end MK43 0AL Cranfield,bedford United Kingdom See on map Links Website Opens in new window EU contribution No data Participants (7) Sort alphabetically Sort by EU Contribution Expand all Collapse all BOC Ltd United Kingdom EU contribution € 0,00 Address 24 deer park road SW19 3UF London See on map Other funding No data EUROPEAN MARINE CONTRACTORS LTD Netherlands EU contribution € 0,00 Address Nieuwe waterwegstraat 3115 HE Schiedam See on map Other funding No data INST DE SOLDADURA E QUALIDADE Portugal EU contribution € 0,00 Address Rua tomas de figueiredo 16 a 1500 Lisboa See on map Other funding No data Isotek Electronics United Kingdom EU contribution € 0,00 Address Royal london industrial estate acorn park charlestown BD17 7SW Shipley See on map Other funding No data MAGUE IND METALOMECANICAS SA Portugal EU contribution € 0,00 Address Est. nacional nø10 2616 Alverca See on map Other funding No data MIGATRONIC A/S Denmark EU contribution € 0,00 Address 9690 Fjerritslev See on map Other funding No data TU DENMARK Denmark EU contribution € 0,00 Address Building 425, st. 2800 Lyngby See on map Other funding No data
