Design and analysis of welding robot in small-diameter pipeline

To address the inefficiency, high labor intensity, safety hazards, and skill dependency of traditional manual welding methods for small-diameter pipelines, this study proposes a newly designed internal welding robot tailored for such pipelines. The robot's key components—including its mobility system, clamping mechanism, welding gun lifting and rotating units, and wire feeding system—were optimized using SolidWorks 3D modeling. These designs enable the robot to move autonomously within the pipe and perform high-quality automated welding through precise mechanical coordination. Virtual simulations using ADAMS software were conducted to evaluate the robot’s clamping motion, climbing ability, and traction performance, confirming the stability and reliability of its movement inside pipelines. Simulation results show that the robot can adapt to complex working conditions. This design significantly enhances welding automation, reduces reliance on manual labor, and offers an efficient solution for small-diameter pipeline welding.