Sensor-Based Weld Travel Speed Measurement During Arc Welding
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Solution Overview
Problem
Manual methods for determining weld travel speed are prone to errors, do not provide real-time feedback, and require additional personnel, making them inefficient and inaccurate.
Innovation Solution
A welding system equipped with sensors and processing circuitry that automatically calculates weld travel speed by measuring the distance traveled by the welding torch and the time difference between sensor indications, enabling real-time feedback and reducing human error.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual methods are used to determine weld travel speed, then additional personnel and equipment are required, but accuracy and efficiency deteriorate due to human error and lack of real-time feedback
Solution Approach 1:
The patent replaces manual mechanical measurement methods (tape measures, stopwatches) with an automated sensor-based system that uses optical or electromagnetic sensors to detect welding arc position and automatically calculate travel speed, eliminating human error and providing real-time data
Solution Approach 2:
The welding system performs self-measurement by using its own sensors to detect the welding arc position and automatically calculate travel speed without requiring external personnel or separate measurement devices, integrating the measurement function into the welding process itself
2Productivity
If manual calculation methods are used, then equipment simplicity is maintained, but productivity deteriorates due to lack of real-time feedback and manual calculation time
Solution Approach 1:
The sensor system continuously monitors the welding arc position throughout the welding process, enabling continuous calculation of travel speed without interruption or pause for manual measurements, thereby maintaining uninterrupted productivity
Solution Approach 2:
The system provides real-time feedback by continuously monitoring welding parameters and calculating travel speed during the welding process, allowing immediate adjustment if needed rather than post-process analysis
3Reliability
If automated sensor systems are implemented, then measurement accuracy and real-time feedback are improved, but device complexity increases
Solution Approach 1:
The sensor system serves multiple functions: detecting welding arc position, measuring travel distance, calculating travel speed, and providing real-time feedback, thereby justifying the added complexity through multiple benefits from a single integrated system
Solution Approach 2:
The patent uses processing circuitry as an intermediary that receives sensor signals, performs automated calculations of travel speed, and outputs results, simplifying the overall system architecture by centralizing the computational function
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides accurate, real-time determination of weld travel speed, enhancing the quality of welds and operator training by eliminating manual calculation errors and enabling immediate feedback during the welding process.
Implementation Method 1
one or more sensors configured to provide a first indication correspond to a welding arc at a first time and to provide a second indication correspond to the welding arc at a second time
Data Source
AI summary
A system and method for determining weld travel speed. In one example, a welding system includes one or more sensors configured to provide a first indication correspond to a welding arc at a first time and to provide a second indication correspond to the welding arc at a second time. The welding system also includes processing circuitry configured to receive the first indication, to receive the second indication, and to determine a weld travel speed based on a weld length of the workpiece and a difference between the first and second times.