Abstract: A system for manufacturing boiler tubes includes a first spindle for receiving a first tube having a first weld preparation, a second spindle for receiving a second tube having a second weld preparation, the first spindle and the second spindle being rotatable synchronously, and a welding device having a first weld head. The welding device is configured to automatically weld the first tube to the second tube according to a control routine stored in memory to produce a boiler tube.

Abstract: A method for manufacturing boiler tubes includes the steps of removing end caps from a plurality of tubes, the plurality of tubes including at least a first tube and a second tube, cleaning an outer surface of the first tube and the second tube, forming a weld preparation on an upstream end of the first tube, forming a weld preparation on a downstream end of the second tube, welding the upstream end of the first tube to the downstream end of the second tube to form a butt weld, to produce a long tube, and with an automated device, measuring a parameter of at least the first tube and the second tube. The steps of removing the end caps, cleaning the outer surface of the tubes, forming the weld preparations, welding the first tube to the second tube, and measuring the parameter are performed autonomously.

Abstract: An automated system for manipulating a workpiece includes a machining device, a locating device configured to determine a position of a workpiece, and a positioning system operatively connected to the machining device and being configured to adjust a position of the machining device to align a centerline of the machining device with a longitudinal axis of the workpiece, based upon the determined position of the workpiece. The machining device includes a stabilizing mechanism to engage the workpiece to maintain the workpiece in the determined position, and a cutting element for performing a machining operation on the workpiece.

Abstract: A method of manufacturing a tube is provided. The method includes: selecting a core pipe having a thickness that is initially less than a desired thickness of the tube; and building-up an outer layer over an exterior surface of the core pipe via additive manufacturing so as to increase the thickness of the core pipe such that the thickness of the core pipe is equal to the desired thickness of the tube.

Abstract: A system for manufacturing boiler tubes includes a first spindle for receiving a first tube having a first weld preparation, a second spindle for receiving a second tube having a second weld preparation, the first spindle and the second spindle being rotatable synchronously, and a welding device having a first weld head. The welding device is configured to automatically weld the first tube to the second tube according to a control routine stored in memory to produce a boiler tube.

Abstract: A waterwall panel welding apparatus is provided. The apparatus includes an inlet assembly, a welding assembly, an outlet assembly, and a heating system. The inlet assembly is for receiving a plurality of tubes. The welding assembly is for receiving the tubes from the inlet assembly and for allowing the tubes to be welded together to form a waterwall panel. The outlet assembly is for receiving the waterwall panel from the welding assembly. The heating system heats the tubes and operates via magnetic induction.

Abstract: A system for manufacturing boiler tubes includes a first spindle for receiving a first tube having a first weld preparation, a second spindle for receiving a second tube having a second weld preparation, the first spindle and the second spindle being rotatable synchronously, and a welding device having a first weld head. The welding device is configured to automatically weld the first tube to the second tube according to a control routine stored in memory to produce a boiler tube.

Abstract: A method for manufacturing boiler tubes includes the steps of removing end caps from a plurality of tubes, the plurality of tubes including at least a first tube and a second tube, cleaning an outer surface of the first tube and the second tube, forming a weld preparation on an upstream end of the first tube, forming a weld preparation on a downstream end of the second tube, welding the upstream end of the first tube to the downstream end of the second tube to form a butt weld, to produce a long tube, and with an automated device, measuring a parameter of at least the first tube and the second tube. The steps of removing the end caps, cleaning the outer surface of the tubes, forming the weld preparations, welding the first tube to the second tube, and measuring the parameter are performed autonomously.

Abstract: A system for locating the position of a component includes, an image capture device, the image capture device being configured to capture an image of a component, a working implement mounted in fixed relation to the image capture device, a positioning system configured to adjust a position of the image capture device and the working implement in relation to the component, and an image processing module in communication with the image capture device, the imaging processing module being configured to receive the image from the image capture device and to identify at least one feature of the component. The positioning system is configured to adjust the position of the image capture device based on a location of the identified feature within the image to align the image capture device with the identified feature, and to align the working implement with the identified feature based upon an offset between the image capture device and the working implement.

Abstract: A system for preserving and capping tubes includes a compressed air reservoir for storing compressed air, a preservative reservoir containing a supply of a preservative, a nozzle in fluid communication with the compressed air reservoir and the preservative reservoir for injecting the preservative into the interior of a tube, and a capping device configured to insert a cap onto the end of the tube.

Abstract: An automated system for manipulating a workpiece includes a machining device, a locating device configured to determine a position of a workpiece, and a positioning system operatively connected to the machining device and being configured to adjust a position of the machining device to align a centerline of the machining device with a longitudinal axis of the workpiece, based upon the determined position of the workpiece. The machining device includes a stabilizing mechanism to engage the workpiece to maintain the workpiece in the determined position, and a cutting element for performing a machining operation on the workpiece.

Abstract: A system for manufacturing boiler tubes includes a first spindle for receiving a first tube having a first weld preparation, a second spindle for receiving a second tube having a second weld preparation, the first spindle and the second spindle being rotatable synchronously, and a welding device having a first weld head. The welding device is configured to automatically weld the first tube to the second tube according to a control routine stored in memory to produce a boiler tube.

Abstract: A method for manufacturing boiler tubes includes the steps of removing end caps from a plurality of tubes, the plurality of tubes including at least a first tube and a second tube, cleaning an outer surface of the first tube and the second tube, forming a weld preparation on an upstream end of the first tube, forming a weld preparation on a downstream end of the second tube, welding the upstream end of the first tube to the downstream end of the second tube to form a butt weld, to produce a long tube, and with an automated device, measuring a parameter of at least the first tube and the second tube. The steps of removing the end caps, cleaning the outer surface of the tubes, forming the weld preparations, welding the first tube to the second tube, and measuring the parameter are performed autonomously.

Abstract: A method of manufacturing a tube is provided. The method includes: selecting a core pipe having a thickness that is initially less than a desired thickness of the tube; and building-up an outer layer over an exterior surface of the core pipe via additive manufacturing so as to increase the thickness of the core pipe such that the thickness of the core pipe is equal to the desired thickness of the tube.

Abstract: A system for preserving and capping tubes includes a compressed air reservoir for storing compressed air, a preservative reservoir containing a supply of a preservative, a nozzle in fluid communication with the compressed air reservoir and the preservative reservoir for injecting the preservative into the interior of a tube, and a capping device configured to insert a cap onto the end of the tube.

Abstract: A system for locating the position of a component includes, an image capture device, the image capture device being configured to capture an image of a component, a working implement mounted in fixed relation to the image capture device, a positioning system configured to adjust a position of the image capture device and the working implement in relation to the component, and an image processing module in communication with the image capture device, the imaging processing module being configured to receive the image from the image capture device and to identify at least one feature of the component. The positioning system is configured to adjust the position of the image capture device based on a location of the identified feature within the image to align the image capture device with the identified feature, and to align the working implement with the identified feature based upon an offset between the image capture device and the working implement.

Abstract: A waterwall panel welding apparatus is provided. The apparatus includes an inlet assembly, a welding assembly, an outlet assembly, and a heating system. The inlet assembly is for receiving a plurality of tubes. The welding assembly is for receiving the tubes from the inlet assembly and for allowing the tubes to be welded together to form a waterwall panel. The outlet assembly is for receiving the waterwall panel from the welding assembly. The heating system heats the tubes and operates via magnetic induction.

Abstract: Disclosed herein is a system having a first housing that includes an optically transparent substrate having a first side and a second side that is opposed to the first side, a camera disposed on the first side of the optically transparent substrate and a source of illumination. The source of illumination is disposed in a ring on the periphery of the first housing and located on the first side of the optically transparent substrate. The system further has a second housing having a circuit board that is operative to process the image captured by the camera, and a battery pack that is operative to supply electrical energy to the source of illumination and to power the circuit board.

Abstract: Disclosed herein is a system having an optically transparent substrate having a first side and a second side that are opposed to each other, a microprocessor, a database, a camera disposed upon the first side of the optically transparent substrate and a source of illumination. The source of illumination is disposed in a ring around the camera on the first side and is operative to illuminate the object disposed on the second side of the optically transparent substrate. Further the camera is in operative communication with the microprocessor and the database. The camera is operative to capture an image of an object disposed upon the second side of the optically transparent substrate. The microprocessor is operative to calculate dimensions and geometry of the object from the image and facilitate acceptance or rejection of the object based upon a standard, a parameter or a calibration chart.

Abstract: Disclosed herein is a system having a first housing that includes an optically transparent substrate having a first side and a second side that is opposed to the first side, a camera disposed on the first side of the optically transparent substrate and a source of illumination. The source of illumination is disposed in a ring on the periphery of the first housing and located on the first side of the optically transparent substrate. The system further has a second housing having a circuit board that is operative to process the image captured by the camera, and a battery pack that is operative to supply electrical energy to the source of illumination and to power the circuit board.