Sensor Torch Based Adaptive Intelligent Control for Circumferential Welding of Pipes

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.