Automated gas tungsten arc welding system for flexible hoses

A gas tungsten arc welding (GTAW) system for automated welding of flexible hoses, comprising:

• a frame having a pneumatic stopper assembly (2), pneumatically connected to an air supply, configured to position and secure flexible hoses for fusion welding at a user-defined location;
• a wire feed spool (1), connected to the frame, configured to supply welding wire;
• an auto pneumatic connector fixture assembly (3), pneumatically connected to the air supply and electrically connected to a control panel, comprising an EC copper-based fixture holder, the fixture assembly configured to align and secure connectors concentrically with fusion-welded hoses for wire feed welding, and controlled via an HMI/touch screen;
• a purging assembly (4), fluidly connected to a gas source, configured to introduce a backflow gas into a weld joint between a connector and a fusion-welded hose during wire feed welding, thereby minimizing oxidation and discoloration;
• a torch and wire feed holder kit (5), mechanically coupled to a motorized Z-axis, Y-axis, and X-axis, configured to position a GTAW welding torch and a wire feed adapter;
• a fixture adapter (6), mechanically coupled to the auto pneumatic connector fixture assembly, configured to accommodate fixtures for connector assembly with varying diameters ranging from ¼ inch to 2 inches;
• a motorized Z-axis (7), electrically connected to the control panel, configured to automatically position the GTAW welding torch along a vertical axis;
• a motorized Y-axis (8), electrically connected to the control panel, configured to automatically position the GTAW welding torch along a horizontal lateral axis;
• a motorized X-axis (9), electrically connected to the control panel, configured to automatically position the GTAW welding torch along a horizontal longitudinal axis;
• a motorized R-axis (10), electrically connected to the control panel, configured to rotate a workpiece clamped in a chuck up to 600 degrees, facilitating welding, pre-purge, post-purge, overlap, and post-weld cooling processes;
• a motorized wire feed axis (11), electrically connected to the control panel and mechanically coupled to the wire feed spool, configured to automatically position the wire feed for connector welding;
• a tower lamp (12), electrically connected to the control panel, configured to indicate operational status, including welding and emergency stop conditions, using color indicators and a buzzer;
• the control panel (13) comprising a programmable logic controller (PLC) further configured to:
• control the movement of the motorized R-axis (10) to execute a variable rotational speed profile during the welding process, wherein the rotational speed is dynamically adjusted based on the angular position of the workpiece to maintain a consistent weld bead formation, thereby enabling the welding of complex geometries,
• control the welding machine (15) to vary the welding current in real-time based on the angular position of the workpiece as determined by the motorized R-axis (10), thus ensuring uniform weld penetration and heat distribution across the weld joint, execute a pre-programmed welding sequence that includes dynamic adjustment of the motorized X-axis (9), Y-axis (8), and Z-axis (7) positions, wherein the adjustment is based on a taught welding path that defines a series of coordinate points and associated welding parameters, thereby enabling precise control of the GTAW welding torch, and control the motorized wire feed axis (11) to synchronize the wire feed rate with the movement of the GTAW welding torch, wherein the synchronization is achieved by correlating the wire feed rate to the instantaneous velocity of the X-axis (9), Y-axis (8), and Z-axis (7), thus ensuring consistent weld filler deposition;
• a cloud monitoring module, configured to provide real-time monitoring of welding parameters and welded components;
• wherein the HMI/touch screen (14) is electrically connected to the control panel, configured to enable user interface for program teaching and parameter settings;
• and
• wherein the welding machine (15) is electrically connected to the control panel and mechanically coupled to the torch and wire feed holder kit, configured to perform gas tungsten arc welding (GTAW) welding operations.