Abstract: An exemplary embodiment of wire wrap welding system generally includes a headstock; a bed; a bed mounted tailstock linearly moveable in relation to the headstock; a linear induction drive system adapted to move the tailstock; a linear encoder system having a series of position encoders disposed on the bed; a servomotor adapted to rotate a headstock mounted spindle; a welding system positioned on the headstock, a servomotor positioned on the tailstock and adapted to rotate a tailstock mounted spindle; and a control system. An exemplary embodiment of a method for controlling slot openings between wire segments in a wire wrap welding process generally includes controlling movement of a bed mounted tailstock in relation to the rate of rotation of a headstock mounted spindle, utilizing a linear induction drive system, a linear encoder system, and a control system.

Abstract: An exemplary embodiment of wire wrap welding system generally includes a headstock; a bed; a bed mounted tailstock linearly moveable in relation to the headstock; a linear induction drive system adapted to move the tailstock; a linear encoder system having a series of position encoders disposed on the bed; a servomotor adapted to rotate a headstock mounted spindle; a welding system positioned on the headstock, a servomotor positioned on the tailstock and adapted to rotate a tailstock mounted spindle; and a control system. An exemplary embodiment of a method for controlling slot openings between wire segments in a wire wrap welding process generally includes controlling movement of a bed mounted tailstock in relation to the rate of rotation of a headstock mounted spindle, utilizing a linear induction drive system, a linear encoder system, and a control system.

Abstract: An apparatus for manufacturing wire wrapped screens utilizing a wire and support ribs is provided. The apparatus employs welding pressure control, utilizing a welding device mounted on a support assembly, wherein the support assembly is moveable in relation to a mounting structure and the wire and support rib weld pieces. Welding pressure is determined by a force measurement device, and a control and feedback system adjusts pressure. Mechanical actuator cylinders mounted on the support assembly and the mounting structure provide load balance. A method for making wire wrapped screens is also provided.

Abstract: An exemplary embodiment of wire wrap welding system generally includes a headstock; a bed; a bed mounted tailstock linearly moveable in relation to the headstock; a linear induction drive system adapted to move the tailstock; a linear encoder system having a series of position encoders disposed on the bed; a servomotor adapted to rotate a headstock mounted spindle; a welding system positioned on the headstock, a servomotor positioned on the tailstock and adapted to rotate a tailstock mounted spindle; and a control system. An exemplary embodiment of a method for controlling slot openings between wire segments in a wire wrap welding process generally includes controlling movement of a bed mounted tailstock in relation to the rate of rotation of a headstock mounted spindle, utilizing a linear induction drive system, a linear encoder system, and a control system.

Abstract: Embodiments of a wire wrapping system generally include a welding wheel electrode mounted on a support assembly, wherein the support assembly is moveable laterally and vertically to a welding position, and moveable laterally and vertically to a sharpening location where a sharpening mechanism can engage the welding wheel electrode contact surface.

Abstract: An apparatus for manufacturing wire wrapped screens utilizing a wire and support ribs is provided. The apparatus employs welding pressure control, utilizing a welding device mounted on a support assembly, wherein the support assembly is moveable in relation to a mounting structure and the wire and support rib weld pieces. Welding pressure is determined by a force measurement device, and a control and feedback system adjusts pressure. Mechanical actuator cylinders mounted on the support assembly and the mounting structure provide load balance. A method for making wire wrapped screens is also provided.

Abstract: Methods and systems for automatically inspecting a wire-wrapped well screen are provided. A camera may capture an image of a portion of the screen including at least two facing edge portions of adjacent wraps of wire defining a slot therebetween. A thickness of the slot may be determined based on the image, for example, by calculating a distance between the facing edge portions. The camera may be moved relative to the screen to measure slot thickness at several sample locations along a length of the screen. The screen may also be rotated relative to the camera to measure slot thickness at sample locations at different angular offset locations around the screen. Slot thickness measured at the sample locations may be analyzed to generate an inspection report that could be supplied to a customer with the well screen.

Abstract: Methods and systems for automatically inspecting a wire-wrapped well screen are provided. A camera may capture an image of a portion of the screen including at least two facing edge portions of adjacent wraps of wire defining a slot therebetween. A thickness of the slot may be determined based on the image, for example, by calculating a distance between the facing edge portions. The camera may be moved relative to the screen to measure slot thickness at several sample locations along a length of the screen. The screen may also be rotated relative to the camera to measure slot thickness at sample locations at different angular offset locations around the screen. Slot thickness measured at the sample locations may be analyzed to generate an inspection report that could be supplied to a customer with the well screen.