Sensor Torch Based Adaptive Intelligent Control for Circumferential Welding of Pipes Navy SBIR FY2005.3 Sol No.: Navy SBIR FY2005.3 Topic No.: N05-154 Topic Title: Sensor Torch Based Adaptive Intelligent Control for Circumferential Welding of Pipes Proposal No.: N053-154-0070 Firm: Adaptive Intelligent Systems 2636 Fireside Circle Lexington, Kentucky 40513 Contact: YuMing Zhang Phone: (859) 223-8058 Abstract: 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. Benefits: Circumferential butt welding of pipes-especially in field applications including shipbuilding, is possibly the single most demanding job for welder skills. For mechanized operation, the joint must be prepared with high precision. With the developed technology, the demand for welder skills and concentration will be greatly reduced. Welders are not required to hold and move the torch smoothly and evenly and their fluctuations in the travel speed and stand-off distance will be tolerated and compensated for by the adaptively adjusted welding parameters. The travel speed will also be increased by 50 percent because welders are not required to excise any extreme cautions. For mechanized orbital systems, this technology implies a tolerance to greater variations in the joint preparation. More importantly, the single-pass weldable wall thickness (for the root pass) will be tripled from 1/8 in. to 3/8 in. because of the use of a controlled quasi-keyhole process. Return