Control system to counteract axial displacement during the welding of huge pipes

Development research has been carried out in order to solve a practical industrial problem: to counteract axial displacement (axial drift or axial creep) of workpieces during the welding process. Solutions found in the literature generally provide adequate results; however, they are mechanically complex with high purchase and maintenance costs. A mechanically simple and inexpensive solution is proposed in this paper. Axial drift is measured with a low-cost custom-built contact displacement sensor. This sensor can measure axial drift without calibration or set-up operations. It is highly robust in order to function correctly in industrial conditions. A pneumatic cylinder moves the idle turning roll along a rail, modifying the longitudinal position of the idle turning roll in order to counteract axial drift. The position of the idle turning roll is controlled by a control algorithm, which consists of a set of rules. Tests were carried out in order to validate the proposed solution, which can be applied to existing turning rolls thereby significantly reducing costs.