Sensor Torch Based Adaptive Intelligent Control for Circumferential Welding of Pipes

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.