Barrel tank seam welder system

Abstract

An apparatus ( 10 ) for joining a predetermined geometrical profile shape from a sheet material (SM) includes a positioning assembly ( 12 ) including a base member ( 14 ) and a frame ( 16 ) that is operable to receive the sheet material (SM), to configure the sheet material in a predetermined orientation and to linearly translate the sheet material along a process direction ( 20 ). A Z-bar ( 22 ) is configured to guide a first longitudinal edge (FE) and second longitudinal edge (SE) of the sheet material (SM) into adjacent alignment along the process direction ( 20 ). A welding and forging assembly ( 60 ) welds and then forges a seam between the first longitudinal edge (FE) and the second longitudinal edge (SE) of the associated sheet material (SM).

1 . An apparatus for welding a predetermined geometric profile shape from an associated sheet material comprising:
 a positioning assembly including a base member and a frame that is operable to receive the associated sheet material, configure the associated sheet material in a predetermined orientation and translate the associated sheet material along a process direction;   a guide member attached to the base member that is configured to guide a first longitudinal edge and a second longitudinal edge of the associated sheet material into adjacent overlapping alignment along the process direction; and   a welding assembly for welding a seam between the first longitudinal edge and the second longitudinal edge of the associated sheet material.   
     
     
         2 . The welding apparatus of  claim 1 , wherein the guide member includes a body having a first channel configured for receiving the first longitudinal edge of the associated sheet material and a second channel configured for receiving the second longitudinal edge of the associated sheet material, the first channel and second channel each include a distal end and a opposite proximal end wherein the associated sheet material is configured to be received at the distal ends and guided into adjacent alignment at the proximal ends. 
     
     
         3 . The welding apparatus of  claim 2 , wherein at least one of the first channel and second channel includes a generally tapered U-shaped profile such that the distal end includes a first profile shape and the proximal end includes a second profile shape such that the first profile shape has a generally wider channel than the second profile shape. 
     
     
         4 . The welding apparatus of  claim 2 , wherein at least one of the first and second channels includes at least one elongated segment, the at least one elongated segment being configured to be movable relative to the body of the guide member to adjust a lateral position of at least one of the first or second longitudinal edges of the associated sheet material for achieving a desired overlap. 
     
     
         5 . The welding apparatus of  claim 4 , further including:
 a controller that is configured to control the welding apparatus such that the at least one elongated segment is automatically movable relative to the body of the guide member to adjust the lateral position of at least one of the first or second longitudinal edges of the associated sheet material as the associated sheet material is linearly translated along the process direction.   
     
     
         6 . The welding apparatus of  claim 5 , further including:
 a sensor configured to sense an overlap of the first longitudinal edge relative to the second longitudinal edge of the associated sheet material and generate an overlap signal.   
     
     
         7 . The welding apparatus of  claim 6 , wherein the controller is further configured to:
 receive the overlap signal;   analyze the overlap signal to determine whether the sensed overlap conforms with a preselected overlap;   move at least one of the plurality of elongated segments until the sensed overlap conforms to the preselected overlap; and   control the welding apparatus to weld the first and second longitudinal edges in coordination with advancement of the associated sheet material as it translates along the process direction.   
     
     
         8 . The welding apparatus of  claim 2 , further comprising a plurality of arms attached to the frame, each arm including a roll, wherein at least one roll is configured to be translated inwardly against the associated sheet material and outwardly away from the associated sheet material to adjust a radial position of the associated sheet material, wherein the plurality of arms are aligned along a common plane on the frame and are radially spaced about a circumference of the associated sheet material. 
     
     
         9 . The welding apparatus of  claim 8 , further including:
 a controller that is configured to control the welding apparatus such that at least one of the plurality of rolls can be automatically translated inwardly against the associated sheet material and outwardly away from the associated sheet material to adjust the radial position of the associated sheet material as the associated sheet material is translated along the process direction.   
     
     
         10 . A method of controlling an apparatus for welding a sheet material into a predetermined geometric profile shape, the method comprising:
 sensing an overlap between a first longitudinal edge and a second longitudinal edge of the sheet material;   comparing the sensed the sensed overlap with a preselected overlap to determine if the sensed overlap conforms with the preselected overlap;   generating a control signal to be received by the welding apparatus to manipulate at least one of a plurality of arms attached to a frame wherein each arm includes a roll such that at least one roll is configured to be translated inwardly against the sheet material and outwardly away from the sheet material to adjust the sensed overlap of the first longitudinal edge and the second longitudinal edge until the sensed overlap conforms to the preselected overlap; and   generating a control signal to be received by the welding apparatus to weld a seam between the first longitudinal edge and the second longitudinal edge of the sheet material.   
     
     
         11 . The method of controlling the welding apparatus of  claim 10  further including:
 generating a control signal to be received by the welding apparatus to manipulate at least one of a plurality of elongated segments configured in relative alignment to receive the first longitudinal edge and the second longitudinal edge of the sheet material, each segment being movable relative to a body of the welding apparatus to adjust the sensed overlap of the first and second longitudinal edges of the sheet material until the sensed overlap conforms to the preselected overlap. 
 
     
     
         12 . The method of controlling the welding apparatus of  claim 11  further including:
 generating a control signal to be received by the welding apparatus to manipulate a robot configured to remove at least one of the plurality of rolls from the arms on the frame of the welding apparatus. 
 
     
     
         13 . The method of controlling the welding apparatus of  claim 11  further including:
 generating a control signal to be received by the welding apparatus to manipulate a robot configured to remove at least one of the plurality of rolls from one of the arms on the frame of the welding apparatus, retrieve a different roll of a different size, and mount the roll of the different size to the one of the arms. 
 
     
     
         14 . The method of controlling the welding apparatus of  claim 11  further including:
 generating a control signal to be received by the welding apparatus to manipulate a feed rate of the sheet material along a process direction. 
 
     
     
         15 . A method of welding a sheet material into a predetermined geometrical profile shape, the method comprising:
 translating a sheet material along a process direction;   receiving a first longitudinal edge of the sheet material within a first channel of a guide member and a second longitudinal edge of the sheet material within a second channel of the guide member;   adjusting a level of overlap of the first longitudinal edge and the second longitudinal edge by positioning the sheet material within the guide member, at least one of the first and second channels of the guide member including at least one elongated segment, the at least one elongated segment being movable relative within the channel of the guide member to adjust a lateral position of at least one of the first and second longitudinal edges of the sheet material;   adjusting the radial position of the sheet material by translating at least one of a plurality of arms inwardly against the sheet material or outwardly away from the sheet material as the sheet material is translated along the process direction; and   welding the first longitudinal edge to the second longitudinal edge.   
     
     
         16 . The method according to  claim 15  further comprising adjusting at least one of the first channel or second channel to position the first longitudinal edge relative to the second longitudinal edge of the sheet material prior to welding.