Abstract: A pipe facing machine (PFM) system includes a PFM and a hydraulic power source having a single hydraulic pump arranged to provide a hydraulic oil flow to the PFM via single hydraulic circuit. The PFM includes a body defining an axis and a cutting head arranged to rotate and translate relative to the axis. Drive systems are arranged to drive clamping of the PFM on a workpiece, rotation of the cutting head about the axis, and translation of the cutting head along the axis. A hydraulic controller includes a plurality of control elements and hydraulically connects the drive systems. The hydraulic controller is arranged to direct and regulate hydraulic oil flow between the drive systems and the hydraulic controller based on signals from the control elements and a computer control system.

Abstract: A rotating machining device for machining a work piece includes a support housing adapted for mounting on the work piece and a headstock rotatably mounted on the support housing about an axis. The headstock including an internal gear. A drive module is arranged to drive rotation of the headstock about the axis and at least one gear connection is formed between the internal gear and the drive module. The at least one gear connection is positioned radially inside of an outer diameter of the support housing to protect an operator from a pinch point associated with the at least one gear connection.

Abstract: A rotating machining device for machining a work piece includes a body having a support housing and a headstock rotatable relative to the support housing. A tool module is mounted to the headstock that includes a tool feed system and an actuating assembly is attached to the support housing. The actuating assembly is arranged to collide with and actuate the tool feed system at a collision point. The radial position of the collision point is adjustable relative to the tool module such that the collision point is repositionable independent of the tool module.

Abstract: A bearing assembly includes a first race having an arcuate configuration and a first set of bearing elements. The first set of bearing elements is arranged to dynamically contact the first race and recirculate within the bearing assembly in a first direction. A second race has an arcuate configuration and is removably secured to the first race. A second set of bearing elements is arranged to dynamically contact the second race and recirculate within the bearing assembly in a second direction opposite the first direction.

Abstract: A method of aligning a portable machining system to a pipe end portion includes automatically moving a measurement sensor mounted to the portable machining system about the pipe end portion in a first measurement plane to generate a first set of measurement data. The method includes translating the measurement sensor from the first measurement plane to a second measurement plane. The method includes automatically moving the measurement sensor about the pipe end portion in the second measurement plane to generate a second set of measurement data and processing the first and second sets of measurement data with a processing module to determine a center and an axis of the pipe end portion.

Abstract: A rotating machining device for machining a work piece includes a support housing adapted to be mounted on the work piece and a headstock rotatably mounted on the support housing. At least one tool module is mounted to the headstock and includes a tool feed system having a tool holder and a feed mechanism operatively connected to the tool holder. A tripper pin assembly is mounted on the support housing and arranged to collide with the feed mechanism for advancement of the tool holder relative to the work piece. The feed mechanism collides with the tripper pin assembly at a collision point radially positioned inside of an outer diameter of the headstock.

Abstract: A rotating machining device includes a segmented support housing arranged to be mounted on a work piece and a segmented headstock mounted on the support housing and rotatable relative to the support housing about an axis. The rotating machining device also includes at least one bearing assembly disposed between the headstock and the support housing. The at least one bearing assembly includes a first race having a first set of bearing elements arranged to dynamically contact a first portion of the headstock and reciprocate within the bearing assembly in a first direction. The at least one bearing assembly also includes a second race having a second set of bearing elements arranged to dynamically contact a second portion of the headstock and recirculate within the bearing assembly in a second direction opposite the first direction so as to promote distribution of a load applied to the bearing assembly.

Abstract: A clamping module for a pipe line-up system uses bell crank linkages to transmit pipe alignment and clamping forces between radially moving clamping feet and a central axially moving driving head. The clamping feet are arranged in axially spaced sets to internally engage two pipe sections to be welded independently on either side of a weld zone between the pipe sections, with welding shoes in between the clamping feet and spanning the weld zone. The bell crank linkages provide a force multiplier between the driving heads and the clamping feet.

Abstract: A method for removing a weld crown from a weld joint between first and second work pieces includes steps of positioning a rotary milling tool proximate to the joint and at an offset angle to set a cutting arc relative to the joint. The milling tool is positioned so the cutting arc intersects the weld crown, weld toes, and parent metal on each side of the weld joint. As the milling tool traverses the joint to cut away the weld crown, the milling tool may tilt from side to side to compensate for misalignment between the work pieces along the weld joint. An apparatus for weld crown removal holds a milling tool at an offset angle, and provides a tracking mechanism to permit the milling tool to track misalignment between the work pieces, maintaining the cutting arc in intersection with the weld toes and parent metal along the weld joint.

Abstract: A method for removing a weld crown from a weld joint between first and second work pieces includes steps of positioning a rotary milling tool proximate to the joint and at an offset angle to set a cutting arc relative to the joint. The milling tool is positioned so the cutting arc intersects the weld crown, weld toes, and parent metal on each side of the weld joint. As the milling tool traverses the joint to cut away the weld crown, the milling tool may tilt from side to side to compensate for misalignment between the work pieces along the weld joint. An apparatus for weld crown removal holds a milling tool at an offset angle, and provides a tracking mechanism to permit the milling tool to track misalignment between the work pieces, maintaining the cutting arc in intersection with the weld toes and parent metal along the weld joint.

Abstract: A cutting tool and mounting system includes a tool carrier arranged to be mounted onto a workpiece, a cutting tool assembly carried by the tool carrier, and a tracking assembly connected to the cutting tool assembly and positioned to follow the contour of an outer surface of the workpiece. The cutting tool assembly includes a cutting tool arranged to be rotated about a longitudinal axis and a tool driving system connected to and arranged to transmit rotary input motion to the cutting tool. The cutting tool is secured by the tool driving system to be fed along its axis of rotation and transversely of its axis of rotation for cutting a workpiece through a wall thickness of the workpiece to impart a beveled surface to a severed end portion of the workpiece.

Abstract: A welding head employs a carriage assembly for guiding the welding head along a track or guide. A torch assembly, mounted on the carriage assembly, is configurable for multiple welding processes. The torch assembly includes a torch block and a GTA filler wire guide mounted together on a mounting plate, whereby the GTA filler wire guide is placed in general proximity of a welding torch mounted on the torch block. The torch block accommodates the mounting of either of a GMA torch and a GTA torch. Additionally, the torch block accommodates placement of a GMA adapter sleeve within the torch block to feed a filler wire through the GMA torch. A system control unit provides manual, semi-automated, or automated control of welding system resources including a welding power supply, a supply of one or more shielding gasses, and a fluid coolant supply.

Abstract: A welding process for non-stainless steel workpieces using GTAW equipment and hydrogen containing shield gas on a first root pass is improved by using a shield gas delivery system comprising hoses or conduits made of elastomeric material having a moisture permeability coefficient of less that 275, preferably less than 100, and using a tungsten electrode composition comprising at least tungsten and lanthanum oxide, and preferably tungsten, lanthanum oxide, yttrium oxide and zirconium oxide. Preventing moisture permeation through the elastomeric hoses delivering hydrogen containing shield gas eliminates expulsion of fused weld metal during second pass filler welding over the root pass weld. Electrode life is enhanced using the tungsten compounds.

Abstract: A welding head employs a carriage assembly for guiding the welding head along a track or guide. A torch assembly, mounted on the carriage assembly, is configurable for multiple welding processes. The torch assembly includes a torch block and a GTA filler wire guide mounted together on a mounting plate, whereby the GTA filler wire guide is placed in general proximity of a welding torch mounted on the torch block. The torch block accommodates the mounting of either of a GMA torch and a GTA torch. Additionally, the torch block accommodates placement of a GMA adapter sleeve within the torch block to feed a filler wire through the GMA torch. A system control unit provides manual, semi-automated, or automated control of welding system resources including a welding power supply, a supply of one or more shielding gasses, and a fluid coolant supply.

Abstract: A cutting tool and track system includes a multi-segment track assembly configured to be removably attached to a surface of a workpiece, a carriage assembly configured to ride along the track assembly, a carriage drive mechanism arranged to drive the carriage assembly along the track assembly, a cutting tool assembly connected to the carriage assembly, and a tool driving system connected to the cutting tool assembly. The cutting tool assembly rotatably supports an end mill type cutting tool that may be driven in a radial cutting plane about the axis of a tubular workpiece or along a workpiece surface. A method is provided for cutting a workpiece wherein a cutting tool assembly rotatably supports an end mill mounted for travel along a predetermined transport path in a cutting plane about a central axis of the workpiece wherein the end mill is first fed through the wall thickness of the workpiece and the cutting tool assembly is moved along the transport path in the cutting plane to cut the workpiece.

Abstract: A system and method for controlling a weld-current in an arc welding apparatus involves programming of a waveform generator to supply a control signal to a weld-current power supply, the control signal being derived from a reference waveform consisting of selected segments having fixed or predetermined amplitudes and variable durations. The reference waveform may be dynamically adjusted in response to changes in welding conditions by feeding the output of an arc current and/or voltage detector back to the waveform generator and varying the duration of selected predetermined amplitude segments.

Abstract: A system for aligning and guiding a weld head or torch along a desired weld path includes a travel mechanism for moving a weld head assembly along a fixed path and a steering mechanism for moving a weld head or torch relative to the fixed path in order to follow a desired weld path. A method of establishing the desired weld path includes the steps of establishing coordinates of the path by moving the weld head or torch to positions along the desired path and recording locations of the weld head or torch at the desired positions. Movement of the weld head or torch between the coordinates is achieved by interpolating a path as the weld head or torch is moved from one coordinate to the next following initiation of an automatic steering program.

Abstract: An arc welding control method and apparatus includes a voltage control loop in which a pulsation parameter such as pulse width, pulse amplitude, background amplitude between pulses, or frequency, is adjusted to compensate for deviations in the arc voltage, and a second, slower feedback loop which adjusts a second parameter of the system in order to cause the pulsation parameter to return to a desired value as a result of the effect of the adjusted second parameter on the arc voltage.

Abstract: A portable machine tool for removing stub ends of heat exchange tubes from a heat exchanger header or other plate structure and preparing the tube opening in the header for butt-welding a new tube at the opening. The tool includes a mandrel that may be locked within the tube opening and a plurality of stabilizing legs extending between the mandrel and the header for stabilizing the mandrel during machine tool operation. A cutting head is mounted concentrically on the mandrel and is advanced into engagement with the stub end of a heat exchange tube and it's respective opening to remove the stub end and prepare the opening for welding the new tube thereon.

Abstract: A portable machine tool for preparing pipe or other annular workpiece ends for welding includes a central mandrel shaft, a cutting head rotatably mounted on the mandrel shaft and a rotary drive connector on the cutting head arranged to concentrically fit within an annular drive head of a modular drive motor unit. The drive motor unit is restrained against torque reactive rotation by a torque reaction bar secured to the mandrel shaft so that relative rotation between the drive motor unit and the mandrel shaft is prevented. The tool is configured so that the annulus of the annular driving head of the drive motor unit can fit axially over the rearward portion of the tool for quick assembly and disassembly. The torque reaction bar is connected by a quick disconnect to the mandrel shaft to facilitate assembly and disassembly of the drive motor unit with a cutting head.