Abstract:
A mechanical system for automatic guiding of one or more torches of a welding unit in a groove delimited by chamfered end surfaces of two metal parts to be welded together, including a main carriage moving along a stationary guide relatively parallel to the groove, a secondary carriage that is connected to the main carriage by a hinged linking assembly and that includes a torch supporting unit and a guiding device including bearing members in contact with the surfaces of the metal parts bordering the groove and sensing members that enter the groove. The hinged linking assembly includes three pivoting axis.

Description:
BACKGROUND 
     The present invention relates to an automatic mechanical guide system for one or more torches of a welding unit, for example an arc-welding unit, in a groove delimited between the two bevelled end surfaces of two metal parts to be welded together, of the type comprising a main bug that moves along a fixed guide substantially parallel to the groove, a secondary bug hinged and attached to the main bug and equipped with a torch holder and a guide device comprising roller components in contact with the surfaces of the metal parts bordering the groove and tracer components that enter the groove, said device comprising two tracer components that are respectively in contact with the two side walls of the groove and are respectively located towards the front and rear of the secondary bug in the direction of movement of the main bug. 
     Generally, an automatic welding machine involves a large number of operating parameters linked to the welding process used, the geometric characteristics of the groove delimited between the two parts to be welded and the welding conditions (nature, shape and position of the parts, etc.). In most industrial applications, the welding operation takes place in several passes, and obtaining a high-quality weld depends on the accuracy with which the first pass is made. It is therefore important that the end surfaces that delimit the groove between them are machined as evenly as possible and that a system capable of following the geometry of the groove is obtained so that the weld is applied very accurately in the bottom of and along the axis of the groove. 
     It is common practice to machine a bevel at the two ends of the parts to be welded. Depending on the angle of the bevel, the groove obtained is flared to a greater or lesser extent; a wide groove increases the number of passes and the welding time and a narrow groove, while it does not present these drawbacks, also poses problems of accuracy for the guide system. 
     Thus, even with such machining, the groove delimited by the two bevels cannot have constant geometric characteristics along its entire length. Once the two end surfaces have been placed opposite each other, the manufacturing tolerances of the parts and the machining tolerances of the bevels will necessarily lead to variations in width and depth in the groove. If the two parts to be welded are relatively long tubes, for example, with a bevel machining tolerance of +/−0.1 mm, this results in a groove width to within +/−0.2 mm with depth of 2 to 3 mm due in particular to the ovalisation of the tubes. 
     If the welding process is gas-shielded electric arc welding, the welding electrodes held by the torches must enter the groove and be located a given distance from the walls and the bottom of the groove or the last weld layer deposited. Under these conditions, the accuracy of the guide system is particularly important, especially when this welding process is used in a narrow groove. 
     Consequently, the accuracy of the weld, particularly on the first pass, involves accurate positioning of the welding electrodes, not only relative to the mid-plane of the groove, but also relative to the bottom of the groove. The more accurate the guide system, the more these two positions, respectively sensitive to variations in groove width and depth, will be observed. 
     To this end, EP 0439975 proposes a guide system that can accurately ensure the positioning of the welding torches inside the groove and is capable of taking into account the width and depth variation of the groove and thus improve the quality of the weld required in certain applications, particularly for the end-to-end welding of sections of tube forming pipelines. 
     Thus, the automatic mechanical guide system for one or more torches on an arc welding unit in a groove delimited by the bevelled end surfaces of two metal parts to be welded together, of the type comprising a main bug that moves along a fixed guide parallel to the groove, a secondary bug that is connected to the main bug by a jointed connecting assembly and is equipped with a torch holder and a guide device comprising roller components in contact with the surfaces of the metal parts bordering said groove and tracer components that enter into the groove. The guide device comprises a first tracer and roller assembly that is located at the front of the secondary bug in the direction of movement of the main bug and comprises a front tracer component in contact with one of the two side walls of the groove and a front roller component rolling on the surface of one of the two metal parts on one side of the groove. The device also comprises a second tracer and roller assembly that is located at the rear of the secondary bug and comprises a rear tracer component in contact with the other side wall of the groove and a rear roller component rolling on the surface of the other metal part on the other side of the groove. The torch(es) are then mounted on the secondary bug so that they are between the first and second tracer and roller assemblies. The jointed connecting assembly comprises a first pivot axis that is perpendicular to the direction of movement of the main bug and is located in a plane parallel to the mid-plane of the groove and a second pivot axis that is perpendicular to the direction of movement of the main bug and perpendicular to the mid-plane of the groove, the first and second pivot axes being located between the first and second tracer and roller assemblies. Lateral pushing means are also provided that act on the secondary bug to urge it to pivot about the first axis so that each tracer component remains in contact with the associated wall of the groove and pushing means that constantly urge the roller components on the second bug against the metal parts respectively associated with them. 
     Through these different positions, the torches being arranged between the tracer components, only a small proportion of the width and depth variations of the groove are passed on to the welding electrodes so that their deviation relative to the mid-plane and the bottom of the groove is reduced to a minimum, which implies improved following of the geometric characteristics of the groove and improved accuracy of the weld. 
     However, it has been noted during operation that during the positioning of the secondary bug on the join plane, the machine axis is sometimes not perpendicular to the axis of the join plane, or the machine axis is sometimes not concentric with the axis of the tubes to be welded. The secondary bug is then moved along the join plane without the tracer and roller assemblies being effective, or it is necessary to reposition the entire welding device. 
     BRIEF SUMMARY 
     Thus, the object of the invention is to propose a system of the type described above in which accurate welding torch positioning is obtained but which also compensates for the inaccurate positioning of the secondary bug to be overcome when it is lowered onto the join plane, particularly to align the axis of the torches with the axis of the join plane even when the axis of the machine is not perpendicular to the axis of the join plane (bevel cuts) or when the machine axis is not concentric with the axis of the tubes (different tube diameters). 
     To this end, the object of the invention is an automatic mechanical guide system for one or more torches of a welding unit in a groove delimited by the bevelled end surfaces of two metal parts to be welded together, of the type comprising a main bug that moves along a fixed guide parallel to the groove, a secondary bug that is connected to the main bug by a jointed connecting assembly and is equipped with a torch holder and a guide device comprising roller components in contact with the surfaces of the metal parts bordering said groove and tracer components that enter into the groove, the device comprising a first tracer and roller assembly that is located at the front of the secondary bug in the direction of movement of the main bug and comprises a front tracer component in contact with one of the two side walls of the groove and a front roller component rolling on the surface of one of the two metal parts on one side of the groove and a second tracer and roller assembly that is located at the rear of the secondary bug and comprises a rear tracer component in contact with the other side wall and a rear roller component rolling on the surface of the other metal part on the other side of the groove, the torch(es) then being mounted on the secondary bug so that they are between the first and second tracer and roller assemblies, the jointed connecting assembly comprising a first pivot axis is that is perpendicular to the direction of movement of the main bug and is located in a plane parallel to the mid-plane of the groove and a second pivot axis that is perpendicular to the direction of movement of the main bug and perpendicular to the mid-plane of the groove, the first and second pivot axes being located between the first and second tracer and roller assemblies, lateral pushing means being provided that act on the secondary bug to urge it to pivot about the first axis so that each tracer component stays in contact with the associated wall of the groove and pushing means that constantly urge the roller components on the secondary bug against the metal parts respectively associated with them, characterised in that the connecting assembly also comprises a third pivot axis that is perpendicular to the direction of movement of the main bug and is located in a plane parallel to the mid-plane of the groove, said third pivot axis being outside the torch holder and pushing means being provided that act on the secondary bug to urge it to pivot about the third axis so that the axis of the torch(es) can be aligned with the axis of the join plane and the secondary bug can then return to its original position. 
     Thus, advantageously, when the secondary bug is brought in line with the bevel axis and is offset relative to this axis, the third pivot axis can be used to position the secondary bug on said bevel axis while the pushing means permit the pivoting and allow the secondary bug to return to its original position after each welding operation. 
     It is understood that when an axis is defined relative to the mid-plane of the groove, this is an ideal reference situation for the mechanical guide system of the invention relative to the join plane, and the pivot axes defined compensate for a non-ideal situation. 
     According to a preferred embodiment, the jointed connecting assembly comprises a connecting arm holding the secondary bug above the groove at one end, and the opposite end of which is mounted on the main bug by means of a hub, said arm being mounted pivoting on the hub about the third pivot axis perpendicular to the direction of movement of the main bug. 
     This third pivot axis is therefore outside the holder of the torch(es) while lateral pushing means are provided that act on the arm to urge it to pivot about the third axis around its original position. 
     Furthermore, by means of the hub, the connecting arm is mounted pivoting on the main bug about a fourth axis, perpendicular to the join plane and the direction of movement of the main bug, it being possible to pivot said connecting arm in a plane substantially parallel to the mid-plane of the groove between a position in which it is lowered to bring the secondary bug onto the join plane to perform a weld and a position in which it is raised once the weld is complete. 
     Thus, when the secondary bug is lowered onto the axis of the bevel using the connecting arm, even if the axis is slightly offset relative to the axis of the arm so that the axis of the tracer and roller means is also slightly offset relative to the axis of the bevel, the pivoting of the arm about the third pivot axis allows for the alignment of the axis of the tracer and roller means, which are thus housed in the groove, and therefore the axis of the torch(es), with the axis of the bevel. Once the weld is complete, the pushing means allow the connecting arm to return to its original position when it is raised. 
     The plane of the bevel may not be entirely perpendicular to the axis of the pipeline under construction, for example if the alignment of the two tubular components to be connected forms a groove that is not perpendicular to the tubular components to be assembled. Thus, if the welding device is positioned perpendicular to the pipeline and the groove is not perpendicular to the pipeline, it will still be possible to follow the join using the mechanical guide system of the invention, the third pivot axis at the hub allowing for the torches to be aligned on the join plane. 
     Similarly, the linear alignment of the tubes to be assembled may not be obtained due to geometric constraints or a linear weld located on the upper part. In this case, the tubes are not aligned and the welding device may not be perpendicular to the tubes or even concentric with them. However, the join can still be followed, the third pivot axis allowing for compensation for the misalignment by pivoting the connecting arm on the hub, and the lowering of the arm onto the join plane restores concentricity. 
     In a preferred embodiment, the secondary bug also has a holder for at least one welding torch, said holder being mobile relative to the secondary bug so that the penetration depth of the at least one welding torch into the groove can be adjusted after each weld pass. 
     Very advantageously, the automatic mechanical guide system for one or more torches of a welding unit in a groove delimited by the bevelled end surfaces of two metal parts to be welded together according to the invention also allows for the proposal of the use of two welding torches independent from each other. 
     According to a preferred variant, the holder holds two welding torches, one of said welding torches being fixed relative to the holder and the other welding torch being mobile relative to the holder so that the penetration depth of said torch can be adjusted independently of the fixed torch. 
     The present invention therefore proposes using at least two torches mechanically connected by the holder, for example in a single welding nozzle and therefore in the same gas shield, but mounted so that they can move up and down independently and are therefore independent in terms of electric arc height where there are electrodes for arc welding. Their automatic controls, such as management of altitude or wire length fed, are independent, and the control laws are therefore separate and the gains are variable. It is therefore possible to combine welding processes with different reaction speeds to the environment within a single welding nozzle. 
     The mechanical guide system according to the invention advantageously enables the use of such a welding head provided with two torches that are each governed by variable control laws that can be configured for each weld pass. The guide system according to the invention allows for full control of the centering of the torches and makes it possible to propose a reference system relative to the edges of the known bevel. 
     Of course, the present invention also applies to welding torches that operate independently of each other and which can also be independent from a mechanical point of view, i.e. held by independent mechanical holders. Similarly, with regard to the gas shield, provision can be made for the use of a separate shield for each torch or a single gas shield by means of a mono-nozzle and mobile side flanges, or any other form of implementation of an appropriate gas shield. 
     When the welding torches are held by the same holder, it is possible to have two types of mechanism. In a first type, the first torch or initial torch is the torch fixed to the holder, which allows for an approach movement and height management, to adjust the wire height fed for a MIG process, to adjust the workpiece-electrode distance for a TIG process, and to adjust the laser altitude for a laser process, while the second torch is the mobile torch, the relative movement of which independently of the movement of the first torch allows for height management as mentioned above. 
     In the second type, the second torch is the fixed torch, which allows for an approach movement and management of the wire height fed while the first torch is the mobile torch, the independent movement of which provides management of the wire fed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will now be described in more detail with reference to the drawing, in which: 
         FIG. 1  shows a general view of a guide system according to the invention; 
         FIG. 2  shows a front perspective view of a connecting arm-secondary bug assembly; 
         FIG. 3  shows a side perspective view of the assembly in  FIG. 2 , with the holder separated from the arm; 
         FIG. 4  shows a side perspective view of a hub for securing the arm to the main bug; 
         FIGS. 5   a  and  5   b  respectively show an extremely diagrammatical view of the top of an arm-secondary bug assembly mounted on a hub; 
         FIG. 6  shows an exploded perspective view of the jointed assembly at the pivot axis A 1 ; 
         FIG. 7  shows an exploded perspective view of the jointed assembly at the pivot axis A 2 ; 
         FIGS. 8   a  and  8   b  respectively show a side perspective view of a holder; and 
         FIGS. 9   a  to  9   h  each diagrammatically show a holder according to variant embodiments of a holder according to the invention. 
     
    
    
     DETAILED DESCRIPTION 
     The automatic mechanical guide system for torches of a welding unit as diagrammatically shown comprises a bug  1  known as the main bug that moves on a circular guide  2  parallel to the circular groove  3 , delimited by the two bevelled end surfaces of two metal tubes  4 ,  5  to be welded together. A bug  7  known as the secondary bug is connected by a connecting assembly to the main bug  1  and holds a holder  8  for two torches  9  forming a welding unit. 
     The secondary bug  7  is fitted with a mechanical guide device comprising tracer components  10   a ,  10   b  and roller components  11   a ,  11   b . The two tracer components  10   a ,  10   b  are offset relative to each other and are respectively located  10   a  at the front of the secondary bug  7  and the other  10   b  at the rear in the direction of movement D of the main bug  1 . The same applies to the position of the two roller components  11   a ,  11   b.    
     The connecting assembly used to connect the secondary bug  7  and the main bug  1  forms a connecting arm  12  one end of which is mounted so that it can be pivoted on the main bug  1  and the other end of which holds the secondary bug  7 . 
     The connecting arm  12  is mounted on the main bug  1  by means of a hub  13  allowing for said arm  12  to be pivoted between a lowered position of the welding unit on the groove  3  between the tubes  4 ,  5  for a welding operation and a raised position of said welding unit when there is no more welding. This hub  13  can therefore be rotated in a plane parallel to the mid-plane of the groove  3  using means of rotation such as a cylinder  14 . This cylinder  14  is for example pneumatic but an electric or hydraulic actuator can also be used. 
     The connecting arm  12  holding the secondary bug  7  is made up of an arm portion  15  connected to a control unit  16  on which is mounted a bracket  17  holding the secondary bug  7 . The control unit  16  is moreover configured to hold the fastenings for the filler wire (filler metal) feeders  18 . 
     The guide device held by the secondary bug  7  is jointed on two pivot axes A 1 , A 2  perpendicular to each other. The axis A 1  is perpendicular to the direction of movement D of the main bug  1  and is located in a plane parallel to the mid-plane of the groove  3  so that the guide device can pivot about this axis A 1  to enable the tracer components  10   a ,  10   b  to follow the geometry of the walls of the groove  3 . 
     The end of the bracket  17  forms a connecting part resting on the base  19   a  of a stirrup  19 . The pivot axis A 1  of the guide device is formed by a pivot one end of which is integral with the base  19   a  of the stirrup  19  and extends perpendicular to it. The pivot shaft A 1  passes through a bearing housed in a hole made in end of the bracket  17  so that its free end opens out into a central opening  17   a  in the bracket  17 . The free end of the pivot shaft A 1  is threaded to receive a nut  21  and thus axially immobilise the pivot shaft A 1 . 
     The axis A 2  is perpendicular to the mid-plane of the groove  3  so that the guide device can pivot about this axis A 2  to enable the roller components  11   a ,  11   b  to follow the geometry of the surfaces of the parts bordering the groove  3 . 
     The pivot shaft A 2  of the guide device perpendicular to the axis A 1  is held by the two flanges  19   b  of the stirrup  19 , and a plate  7   a  of the secondary bug  7  that holds the guide device is jointed on the pivot shaft A 2 . Thus, the guide device can pivot on the one hand directly about the axis A 2  and on the other hand inside the bearing by means of the stirrup  19  and the axis A 1 . 
     The secondary bug  7  is constantly subject to thrusts that are passed on respectively to the tracer components  10   a ,  10   b  and the roller components  11   a ,  11   b.    
     Thus, the stirrup  19  holds at its base, between the two flanges of the stirrup  19 , a lever arm  20   a  protruding perpendicular to the axis A 1  and extending in a plane perpendicular to the plane in which the axis A 1  extends. The end of the bracket  17  comprises a pushing component  20   b  extending perpendicular to the lever arm  20   a  in the same plane. This pushing component  20   b  therefore exerts thrust on said lever arm  20   a , making the stirrup  19  rotate about the axis A 1  while stops  22  (screw/washer) fixed to the end of the bracket  17  limit the rotational movement of the stirrup  19 . 
     When it lowers the connecting arm  12  onto the join plane, the cylinder  14  exerts a force on the secondary bug so that it is constantly pushed by means of the roller components  11   a ,  11   b  on the guide device onto the parts  4 ,  5 . 
     Moreover, the guide system is jointed along a third pivot axis A 3  perpendicular to the direction of movement of the main bug  1  and parallel to the mid-plane of the groove  3 , said axis A 3  outside the torch holder  8  and also outside the secondary bug  7  being located level with the hub  13  holding the connecting arm  12  on the main bug  1 . This hub  13  is mounted so that it can be rotated about a pivot axis A 4  on the main bug  1  by means of a fixing plate  13   a  and has on its periphery a radially protruding lug or tab  13   b  at the end of which is mounted the end of the rod of a cylinder  14 , the actuation of the cylinder  14  moving the end of the protruding lug  13   b  in translation and causing the hub  13  to be rotated relative to the main bug  1  about the axis A 4 . 
     This hub  13  also holds a stirrup  22  the flanges  22   a  of which respectively have an aperture  22   b  in which is housed one end of the arm  12  holding at its other end the secondary bug  7 . The base  22   b  of the stirrup  22  is also fixed to the hub  13  so that it pivots about said third pivot axis A 3 , pushing means such as springs  23  being provided that act on the base  22   b  of the stirrup  22  to urge it to pivot about said third axis A 3 . 
     Thus the hub  13  holding the connecting arm  12  equipped with the secondary bug  7  can be pivoted on the one hand between a raised position of the secondary bug  7  relative to the groove  3  and a lowered position onto the groove  3 . But furthermore, the pivoting movement of the arm  12 , and therefore of the bug  7  and therefore of the guide system about the pivot axis A 3  makes it possible to align the axis of said arm  12  with the axis of the groove  3  (see  FIG. 5   b ) even when the axis of said arm  12  is slightly offset from the axis of the groove  3  (see  FIG. 5   a ). 
     By pivoting the arm  12  about the axis A 3 , the guide system, which is slightly offset, repositions itself in the groove  3  in an appropriate manner. Once the welding is complete, the secondary bug  7  is raised and the pushing means  23  return the arm  12  to its original position. 
     In the example shown, the holder  8  holds two torches T 1  and T 2  located between the two tracer and roller assemblies  10   a ,  11   a  and  10   b ,  11   b.    
     The holder  8  is removable from the secondary bug  7  as shown in the figure and it is also mobile relative to said secondary bug  7  so that the penetration depth of the electrodes E 1  and E 2  into the groove  3  can be adjusted after each weld pass. To this end, the holder  8  is mounted sliding along two slide rails held by the plate  7   a  of the secondary bug  7 . For accurate adjustment of the penetration depth of the electrodes E 1  and E 2 , stops of different heights are also provided, mounted on a rotating drum. A cylinder secured to the plate on the secondary bug  7  has its piston rod integral with the holder to move it along the slide rails in order to bring a pin of the holder  8  in contact with the stop selected on the drum. Furthermore, an oscillation movement can be imparted to the holder  8  with a frequency and amplitude adjustable by a mechanical or electrical means known per se. 
     In addition for greater accuracy and to manage the intensity. The wire length fed defines the resistance of the arc (R) and the arc voltage is kept constant by the generator (U). Acting on the wire length by moving closer to the weld bead makes it possible to reduce R, and moving away from the weld bead makes it possible to increase R, which constitutes acting on the intensity (I) value “HOM”. The holder  8  holds two welding torches connected mechanically but independent in height, one of said welding torches T 1  being fixed relative to the holder  8  and the other welding torch T 2  being mobile relative to the holder  8  so that the penetration depth of said torch T 2  can be adjusted relative to the fixed torch T 1 . 
     It is then possible to have two types of mechanism. In a first type, the first torch or initial torch is the fixed torch T 1  on the holder  8 , which makes possible an approach movement and management of the wire height fed while the second torch is the mobile torch T 2 , the relative movement of which independently of the movement of the first torch allows for management of the wire fed (cf.  FIG. 8   a ). 
     In the second type, the second torch is the fixed torch T 1 , which allows for an approach movement and management of the wire height fed while the first torch is the mobile torch T 2 , the independent movement of which provides management of the wire fed (cf.  FIG. 8   b ). 
     The mobile torch T 2  is mounted sliding along a slide rail  24  arranged on the holder  8 . 
     The invention is of course in no way limited to the examples given, but also encompasses all of the variants as shown in  FIGS. 9   a  to  9   h.    
     Thus,  FIGS. 9   a  and  9   b  show a holder holding two torches T 1 , T 2  filed to the holder, it being possible for said holder to be fixed relative to a shop ( Figure 9   a ) or mobile ( FIG. 9   b ), which allows for wire length control. 
     The holder in  FIGS. 9   c  and  9   d  holds a mobile torch and a fixed torch, said holder being fixed to a stop in  FIG. 9   c  while the other torch, which can move up and down relative to the block, allows for wire length management on said torch. 
     In  FIGS. 9   e  and  9   f , the holder can move up and down and holds a fixed torch as well as a torch that can move up and down relative to the holder. Wire length management on both torches is therefore proposed. 
     In  FIGS. 9   g  and  9   h , a block is proposed that holds two torches that can move up and down on said block, with the block being fixed to a stop in  FIG. 9   g  while in  FIG. 9   h  it is mounted so that it can move both up and down. 
     The invention is of course in no way limited to the examples given. 
     Figure Text 
     
         
           7 / 8   8   a / 8   b : Direction of welding 
           8 / 8   9   a - 9   h : Mechanical stop
       Upper stop (parked) Movable up and down   Direction of welding Mechanical stop cylinder