System, method and apparatus for welding tubes

1. A system for manufacturing boiler tubes, comprising:

a first spindle for receiving a first tube having a first weld preparation;

a second spindle for receiving a second tube having a second weld preparation, the first spindle and the second spindle being rotatable synchronously;

a welding device having a first weld head; and

a vision system configured to capture an image of a weld groove defined by the first weld preparation and the second weld preparation;

wherein the welding device is configured to automatically weld the first tube to the second tube in dependence upon a plurality of weld and tube parameters received by a control unit of the system; and

wherein the control unit is configured to compare the image of the weld groove to weld groove profiles stored in memory to determine a weld groove type from the image of the weld groove, and to select a weld routine in dependence upon the determined weld groove type, a type of material of the first tube and the second tube, and an outside diameter of the first tube and the second tube.

2. The system of claim 1 , wherein:

the control unit is configured to rotate the first spindle and the second spindle synchronously at a predetermined rate dictated by the control unit in dependence upon the plurality of weld and tube parameters.

3. The system of claim 1 , wherein:

the vision system is configured to locate a bottom dead center of the weld groove; and

the welding device is configured to move the first weld head into position at a center, bottom of the weld groove based upon information obtained by the vision system.

4. The system of claim 1 , wherein:

at least one of the first spindle and the second spindle is movable axially to bring the first tube and the second tube into touching contact.

5. The system of claim 1 , further comprising:

a position stop intermediate the first spindle and the second spindle, the position stop being movable between a raised position in which the position stop limits axial movement of the first tube and the second tube, and a lowered position in which the first tube and the second tube are movable beyond the position stop.

6. The system of claim 1 , wherein:

the first weld head is removable from the welding device during a weld cycle.

7. The system of claim 6 , further comprising:

a docking station having a plurality of weld heads each having a different consumable wire type;

wherein the welding device is configured to remove the first weld head and retrieve one of the plurality of weld heads from the docking station during the weld cycle.

8. The system of claim 7 , further comprising:

a cleaning station configured to automatically clean at least a portion of the first weld head, spray anti-spatter and jog a wire of the first weld head forward during the weld cycle prior to removing the first weld head.

9. The system of claim 1 , further comprising:

a user interface having an input device and a display device;

wherein the input device allows an operator to select a weld routine for carrying out a weld cycle.

10. The system of claim 9 , further comprising:

a heating device configured to preheat the tubes to a predetermined temperature prior to welding;

wherein the control unit is configured to position the heating device in close proximity to the first tube and the second tube, to activate the heating device until the predetermined temperature is reached, and to retract the heating device upon completion of preheating.

11. A system for welding tubes, comprising:

a first spindle for receiving a first tube having a first weld preparation;

a second spindle for receiving a second tube having a second weld preparation, the first spindle and the second spindle being rotatable synchronously, the first spindle being movable axially towards the second spindle to move the first tube into contact with the second tube to form a weld groove;

a welding device having a first weld head;

a vision system configured to capture an image of the weld groove defined by the first weld preparation and the second weld preparation; and

a control unit configured to compare the image of the weld groove to weld groove profiles stored in memory to determine a weld groove type from the image of the weld groove, and to select a weld technique in dependence upon the determined weld groove type, a material of the first tube and the second tube and an outside diameter of the first tube and the second tube;

wherein the control unit is further configured to control the welding device and the first weld head according to the weld technique stored in memory determined weld groove type.

12. The system of claim 11 , wherein:

the weld technique is dependent upon a weld groove type.

13. The system of claim 11 , further comprising:

a second weld head having a consumable wire electrode that is different from a consumable wire electrode of the first weld head;

wherein the second weld head is interchangeable with the first weld head during the weld cycle without manual intervention by an operator.