Fiber Optic Weld-Line Sensing for Induction Welding Control
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Solution Overview
Problem
Controlling the temperature during induction welding of thermoplastic composite parts is challenging, leading to inconsistencies in the weld quality if not performed within a specific temperature range.
Innovation Solution
The use of remote sensing technologies, specifically linear fiber optic sensors, to measure and control the temperature along the weld line during induction welding, allowing for real-time adjustments to ensure the temperature remains within the desired range without the need for sensors at the weld interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are placed directly at the weld interface to measure temperature, then temperature measurement precision is improved, but device complexity and cost increase due to requiring temperature-resistant sacrificial sensors
Solution Approach 1:
The patent uses an intermediary approach by placing fiber optic sensors near the weld interface rather than directly at it, allowing temperature measurement through thermal conduction from the weld zone. This intermediary positioning avoids the need for temperature-resistant sacrificial sensors while still enabling accurate temperature monitoring through the sensor's connection to the weld interface.
Solution Approach 2:
The patent replaces traditional mechanical contact temperature sensors (thermocouples) with fiber optic sensors that use optical principles for measurement. This substitution eliminates the need for temperature-resistant materials and sacrificial sensors, as fiber optic sensors can operate remotely and transmit temperature data through light signals without being directly exposed to extreme temperatures.
2Measurement precision
If sensors are placed directly at the weld interface, then temperature monitoring accuracy is improved, but weld strength decreases due to interference with the welding process
Solution Approach 1:
By positioning sensors near rather than directly at the weld interface, the patent creates an intermediary measurement system that does not interfere with the welding process. The sensors monitor temperature through thermal conduction from the weld zone without physically obstructing the interface or requiring sacrificial materials that would compromise weld strength.
Solution Approach 2:
The patent extracts the temperature sensing function from the weld interface itself, placing sensors in a nearby location where they can measure temperature without being part of the weld structure. This separation allows accurate temperature monitoring while preserving the integrity and strength of the weld interface.
3Measurement precision
If traditional temperature-resistant sensors are used at the weld interface, then temperature measurement is achieved, but cost increases due to requiring sacrificial sensors
Solution Approach 1:
The patent replaces expensive temperature-resistant sacrificial sensors with fiber optic sensors that use optical measurement principles. This substitution eliminates the need for specialized high-temperature sensor materials, significantly reducing cost while maintaining temperature measurement capability through remote sensing and optical signal transmission.
Solution Approach 2:
Instead of using expensive sacrificial sensors that must withstand extreme temperatures, the patent employs a non-sacrificial fiber optic sensor system that operates remotely. The fiber optic sensors are not consumed or damaged by the welding process, eliminating the need for costly replacement and reducing overall measurement system cost.
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
This method enhances weld strength, reduces costs, and ensures consistent weld quality by accurately monitoring and controlling the temperature along the weld line, eliminating the need for temperature-resistant sensors at the weld interface.
Implementation Method 1
measuring temperatures along the weld line via the linear fiber optic sensor
Implementation Method 2
measuring temperatures along the weld line via the linear fiber optic sensor
Implementation Method 3
an end effector that generates an electromagnetic field which causes a weld line of a composite part to generate heat resulting in induction welding
Implementation Method 4
generates an electromagnetic field which causes a weld line of a composite part to generate heat resulting in induction welding
Data Source
AI summary
Systems and methods are provided for controlling welding. One embodiment is a method for controlling welding of a composite part. The method includes locating a linear fiber optic sensor along a composite part comprising a matrix of thermoplastic reinforced by fibers, measuring temperatures along the weld line via the linear fiber optic sensor, performing induction welding at the composite part along the weld line, determining a continuum of weld temperatures along the weld line, and controlling the induction welding based on the continuum of weld temperatures.