currently Hailing from Houston Texas, Bryan King is a Mechanical Engineer and Machine Designer. Contact him at supertuber@gmail.com

The E-head

The E-head

The E-head is a specialized, semi-automated, weld head. It's purpose is to quickly butt-weld tubes during the replacement of the super-heater section of a coal fired power plant. The E-head has a narrow side clearance, a requirement of the application due to the tight spacing of the rows of tubing in the super-heater section. The head can be assembled from one side of the super-heater row. The travel, arc strike, surface following and oscillation of the head are automatic. The weld wire position is a quick touch adjustment made by the operator at the beginning of each pass. Development of this head allowed machine welds to be performed in clearances that previously required manual welds. 

 The E-head (left) and wire feeder (right).  

The E-head (left) and wire feeder (right).  

 The rotating portion of the head.  From the top-down: TIG torch block and wire manipulator. The torch block rests on a pivoting arm which maintains the weld arc gap during the weld. The rotor floats on a series of V-rollers in a link chain. The rotor splits in half and allows the head to be assembled around the tube. Also visible to the left is a clutch lever to disengage the rotor drive, allowing the rotor to be manually rotated for setup.

The rotating portion of the head.  From the top-down: TIG torch block and wire manipulator. The torch block rests on a pivoting arm which maintains the weld arc gap during the weld. The rotor floats on a series of V-rollers in a link chain. The rotor splits in half and allows the head to be assembled around the tube. Also visible to the left is a clutch lever to disengage the rotor drive, allowing the rotor to be manually rotated for setup.

 An exploded view of the rotor assembly. 

An exploded view of the rotor assembly. 

 A view of the front of the weld head. Water cooling blocks are visible (copper color) on the lower portion of the head. The T-handle on the left is the V-wheel link assembly attachment and tension. The clutch lever is visible on top of the drive assembly (blue). 

A view of the front of the weld head. Water cooling blocks are visible (copper color) on the lower portion of the head. The T-handle on the left is the V-wheel link assembly attachment and tension. The clutch lever is visible on top of the drive assembly (blue). 

 An exploded view of the drive assembly. 

An exploded view of the drive assembly. 

 The wire manipulator assembly. 2 axis of motion in a small package.

The wire manipulator assembly. 2 axis of motion in a small package.

Pick and place robotic cells

ANO NGS core flood nozzle

ANO NGS core flood nozzle