Title of Invention

A CONTACT OR NON-CONTACT TYPE DIGITAL APPARATUS FOR MEASURMENT OF FILLET WELD SURFACE PROFILE

Abstract

A contact or non-contact type digital gauge apparatus for measurement of fillet weld surface profile comprising of two measuring devices (5) and (6) mounted on a slide (7) and integrated with a processing unit with a built-in algorithm, a base (4) fixed on a horizontal part (2), a vertical shaft guide (3) mounted on the base, the two measuring devices (5 & 6) measuring the distances between the measuring devices and selected locations (such as A, B, C & D) on the fillet (8) and above the fillet, one device (5) measuring at selected points the distances from this device to the vertical part of the component joined to the horizontal part by the fillet (8) and the other device (6) measuring the distances between the measuring device and the horizontal surface (base) of the component for all the selected points measured by the other device (5), feeding the measured distances as data inputs in a processing unit and computing the fillet dimensions through a built-in algorithm in the processor and displaying the same in a display device.

Full Text

-2- FIELD OF THE INVENTION This invention refers to the development of Digital gauge for measuring various dimensions of a completed fillet weld. BACKGROUND OF THE INVENTION Fillet weld is a weld at the junction of two parts, e.g. plates at right angles to each other, in which a fillet of welding metal is laid down in the angle created by the intersection of the surfaces of the parts. Fillet welds are widely used in several applications either as single pass weld or a multi-pass weld. This involves welding of different thickness material which may be of steel or non ferrous categories. At least one of the edges joined may also have edge preparations. During welding one of the members may distort so that the initial angle between the two components before welding may be changed due to distortion. In practical conditions the weld gauge has to take in to consideration the factors like the surface profile of the fillet, equal or unequal leg sizes, the angle between the components joined etc. while measuring the weld dimensions. -3- The mechanical gauges have been developed and applied for this purpose. However, in the application of these gauges, the accuracies are limited by nature of the bead surface - Concavity / Convexity or metere joint and the angle between plate surfaces joined by the fillet. In order to eliminate these difficulties a new type of gauge is proposed which would give a digital output of the leg sizes and throat size of he fillet after the required measurements and calculations. In addition the gauge can be used for measuring the edge preparation angle of a bevel edge prepared plate/pipe. As prior art references in this field Patent No. GB439319 has described a gauge for checking dimensions relating to welded joints in which one or more blade like members, shaped and dimensioned at the ends and/or sides in accordance with suitable shapes and sizes for said joints, are pivoted in a holder, so as to be opened out for use and closed into the holder when not in use. -4- Document W00221071 has disclosed an adjustable gauge having special application to the measuring of the dimensions of a fillet weld. The gauge includes a first plate and a second plate wherein the plates are rotatably mounted about an axis of rotation and juxtaposed to one another. The gauge also includes a linear member rotatably mounted on the same axis of rotation as the first and second plates juxtaposed to the second plate on a first face opposite the first plate. The linear member is slidably mounted in relation to the first and second plates in order to extend so as to measure the dimension of a weld. The first plate is substantially rectangular in shape and terminates in an edge, which traverses one corner thereof. The second plate is substantially circular in shape. A front face of the first plate, which is adjacent to the second plate, has a recess thereon sized to accommodate the second plate. The first plate, the second plate, and the linear member are rotatably mounted to one another with a spring based mechanism for increasing and decreasing the rotational resistance there between. The above state of prior art suffers from the difficulties that the gauges are limited in accuracies in measurement of dimensions in respect of complex formation of weld profile and change of angle between the two members during welding. -5- OBJECTS OF THE INVENTION One object of the present invention is to develop a non-contact type digital measurement apparatus for measuring the leg sizes of the fillet welds, which may be equal or unequal leg sizes. Another object of the invention is to measure the throat size of the fillet weld that may have a concave or convex weld profile. Yet another object of the invention is to measure the angle of edge preparation. A further object of the invention is to carry out the measurement through non- contact measurement systems by using a single mathematical program for arriving at the desired dimensions. According to the invention there is provided a contact or non-contact type digital gauge apparatus for measurement of fillet weld surface profile comprising of two measuring devices mounted on a slide and integrated with a processing unit with a built-in algorithm, a base fixed on a horizontal part, a vertical shaft guide -6- mounted on the base, the two measuring devices measuring the distances between the measuring devices and selected locations (such as A, B, C & D) on the fillet and above the fillet, one device measuring at selected points the distances from this device to the vertical part of the component joined to the horizontal part by the fillet and the other device measuring the distances between the measuring device and the horizontal surface (base) of the component for all the selected points measured by the other device, feeding the measured distances as data inputs in a processing unit and computing the fillet dimensions through a built in algorithm in the processor and displaying the same in a display device. DESCRIPTION OF THE INVENTION In this invention, an apparatus has been developed to measure the sizes of a fillet weld. This apparatus is making use of two, length - measuring gauges fixed along a vertical shaft. The out put of the gauges are displayed by a digital meter. Also, the outputs can be fed to a micro controller based processing unit, which will process the digital data and give the digital output of fillet weld sizes. The -7- apparatus can also measure with ease, equal or unequal fillets, concave, convex or flat profiles of the fillet and any angle between the surfaces joined by the fillet. The length - measuring gauge can be either contact or non-contact type. The proposed invention will be better understood from the following description in which Figure 1 shows schematically the essential features of the apparatus for the measurement of the weld dimensions. Fillet weld is made between the two parts (1) and (2) A vertical guide (3) is mounted on a base (4) fixed on the part (2). The base will be suitable for mounting on flat as well as curved surfaces. Two, distance measuring devices (5) and (6) are mounted on a slide (7). The weld (8) is made to join 1 and 2. A, B, C and D are locations where measurements are made. X1 and H1 are the distances measured at location A. -8- The apparatus has two distance measuring systems. One measuring device (5) will measure the distance from this measuring device to the vertical part of the component, which is joined to the horizontal part by the fillet. This measuring device will measure the distance at four points. One (A) of this will be above the fillet, two (B & D) at the toes of the fillet and one (C) at the maximum concavity or convexity on the fillet profile. The other measuring device (6) will measure distance between the measuring device and the horizontal surface (base) of the component for all the four points measured by the other measuring device. The base of the apparatus is designed to enable setting the apparatus on a flat surface or a curved surface. The base has a vertical shaft (3) on which the distance measuring devices are suitably mounted on a slide (7). The slide moves vertically up and down and it is operated manually to position the measuring devices at suitable positions for carrying out the measurement at four points as described above. The output from the measuring devices in the digital form are fed to a processing unit. The data input are processed using a mathematical program, built-in to the processor. The output from the processor can be displayed digitally through a display device. The processed data provided two leg lengths and the actual throat of the fillet. -9- The algorithm used the processor has been developed for the purpose of measurement has the following mathematical characters for measuring vertical and horizontal parts of the fillet through measuring distances between measuring devices and the fillet for vertical and horizontal surface of the fillet. Known input θ1 Measured Data: D1, D2, D3, D4, H1, H2, H3, H4 Computed Data: θ2, θ3, h1, h2, h3, h3, d1, d2, d3, d4, T, L1, L2 h1=H1 - D1 sin θ1 D1 = D1 cos θ1 h2= H2 - D2 sin θ1 d2 = D2 cos θ1 h3= H3 - D3 sin θ1 d3 = D3 cos θ1 h4 = H4 - D4 sin θ1 d4 = D4 cos θ1 θ2 = Tan-1 [(h1-h2)/(d2-d1)] X1 = h2/tanθ2 L1 = h2/sinθ2 For positive d2-d1 L2 = X1 + (d2-d3) -10- If d2-d1 is negative L2 = (d2-d3)-X1 θ3 = Tan-1 [h2/(d2-d3)] For metere & convex profile of the fillet Throat T = L2sinθ3 Y = (h2-h4) - [(d2-d3) tanθ3] Z = sin(90-θ3) Y For concave fillet profile Throat Tc =T - Z The proposed invention is illustrated with the following practical example of computed fillet dimensions of its two leg length and throat. Example of Measured Data For Measured Data set 1: H1= 51.32 H2= 36.05 H3= 24.25 H4= 30.19 -11- D1= 52.64 D2= 56.11 D3= 48.50 D4= 53.39 Computed values: Theta2=79.9622 Theta3=50.50 Concave Throat tc= 5.45 For Measured Data set 2: H1=51.32 H2=37.85 H3=20.21 H4=32.27 Dl=52.64 D2=55.70 D3=40.41 D4=52.47 -12- Computed values: Theta2=79.98 Theta3=37.06 Concave Throat tc=7.552 The invention as narrated herein should not be read as construed in a restrictive manner as various modifications, alterations and adaptations are possible within the scope and ambit of the invention as defined in the encompassed appended claims. -13- WE CLAIM 1. A contact or non-contact type digital gauge apparatus for measurement of fillet weld surface profile comprising of: - two measuring devices (5) and (6) mounted on a slide (7) and integrated with a processing unit with a built-in algorithm, a base (4) fixed on a horizontal part (2), a vertical shaft guide (3) mounted on the base, the two measuring devices (5 & 6) measuring the distances between the measuring devices and selected locations (such as A, B, C & D) on the fillet (8) and above the fillet, One device (5) measuring at selected points the distances from this device to the vertical part of the component joined to the horizontal part by the fillet (8) and the other device (6) measuring the distances between the measuring device and the horizontal surface (base) of the component for all the selected points measured by the other device (5), feeding the measured distances as data inputs in a processing unit and computing the fillet dimensions through a built in algorithm in the processor and displaying the same in a display device. -14- 2. The digital gauge apparatus for measurement of fillet weld surface profile as claimed in claim 1 wherein the location A is above the fillet, B & D at the toes of the filtet, and C is at the maximum concavity or convexity of the fillet profile. 3. The digital gauge apparatus as claimed in claim 1 wherein the devices (5) and (6) are sensors, measuring the distances in digital form via a digital meter. 4. The digital gauge apparatus as claimed in claims 1 and 3 wherein the positions of the sensors (5 & 6) can be altered slidably through vertical movement by the vertical guide (3). 5. The gauge apparatus as claimed in claim 1 wherein the base (4) is suitably designed to set the measuring sensors on flat, cylindrical or any other curved surface jobs. -15- 6. The gauge apparatus as claimed in the preceding claims wherein measurement made from the distance sensors are fed as inputs into a data processing unit inbuilt with an algorithm developed for the purpose, to compute biaxial components of fillet dimensions measured at the toes and top position of the fillet and display the measured dimensions of the fillet in a display device. 7. The gauge apparatus as claimed in claim 6, wherein the vertical components D1, D2, D3, D4 and horizontal components of the fillet and angle of edge (θ2, θ3) are measured through a developed algorithm for the purpose according to the mathematical steps of Known input θ1 Measured Data: D1, D2, D3, D4, H1, H2, H3, H4 Computed Data: θ2, θ3, h1, h2, h3, h3, d1, d2, d3, d4, T, L1, L2 h1=H1 - D1 sin θ1 D1 = Di cos θ1 h2= H2 - D2 sin θ1 d2 = D2 cos θ1 h3= H3 - D3 sin θ1 d3 = D3 cos θ1 h4 = H4 - D4 sin θ1 d4 = D4 cos θ1 -16- θ2 = Tan-1 [(h1-h2)/(d2-d1)] X1 = h2/tanθ2 L1 = h2/sinθ2 For positive d2-d1 L2 = X1 + (d2-d3) If d2-d1 is negative L2 = (d2-d3) - X1 θ3 = Tan-1 [h2/(d2-d3)] For metere & convex profile of the fillet Throat T = L2sinθ3 Y = (h2-h4) - [(d2-d3) tanθ3] Z = sin(9O-θ3) Y For concave fillet profile Throat Tc =T - Z 8. The gauge apparatus as claimed in the preceding claims wherein the sensors integrated with the processors enable to determine two leg lengths, actual throat size, angle between the surfaces of the job components joined by the fillet, angle of chamfer in a plate or pipe and surface profile of fillet as a whole whether regular or irregular through the built in algorithm with steps of mathematical calculation. -17- 9. A contact or non contact type digital gauge apparatus for measurement of fillet weld surface profile as herein described and illustrated. Dated this 22nd day of March 2007. A contact or non-contact type digital gauge apparatus for measurement of fillet weld surface profile comprising of two measuring devices (5) and (6) mounted on a slide (7) and integrated with a processing unit with a built-in algorithm, a base (4) fixed on a horizontal part (2), a vertical shaft guide (3) mounted on the base, the two measuring devices (5 & 6) measuring the distances between the measuring devices and selected locations (such as A, B, C & D) on the fillet (8) and above the fillet, one device (5) measuring at selected points the distances from this device to the vertical part of the component joined to the horizontal part by the fillet (8) and the other device (6) measuring the distances between the measuring device and the horizontal surface (base) of the component for all the selected points measured by the other device (5), feeding the measured distances as data inputs in a processing unit and computing the fillet dimensions through a built-in algorithm in the processor and displaying the same in a display device.

Documents:

00454-kol-2007-abstract.pdf

00454-kol-2007-claims.pdf

00454-kol-2007-correspondence others 1.2.pdf

00454-kol-2007-corrospond others.pdf

00454-kol-2007-description complete.pdf

00454-kol-2007-drawings.pdf

00454-kol-2007-form 18.pdf

00454-kol-2007-form 2.pdf

00454-kol-2007-form 3.pdf

00454-kol-2007-gpa.pdf

454-KOL-2007-(14-09-2011)-ABSTRACT.pdf

454-KOL-2007-(14-09-2011)-AMANDED CLAIMS.pdf

454-KOL-2007-(14-09-2011)-DESCRIPTION (COMPLETE).pdf

454-KOL-2007-(14-09-2011)-DRAWINGS.pdf

454-KOL-2007-(14-09-2011)-EXAMINATION REPORT REPLY RECIEVED.pdf

454-KOL-2007-(14-09-2011)-FORM 1.pdf

454-KOL-2007-(14-09-2011)-FORM 13.pdf

454-KOL-2007-(14-09-2011)-FORM 2.pdf

454-KOL-2007-(14-09-2011)-OTHERS.pdf

454-KOL-2007-FORM-27.pdf

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