Force-Sensing Welding Torch Control Without Foot Pedals
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Solution Overview
Problem
Current remote control systems for welding machines, such as foot pedals and hand controls, are cumbersome, impractical in hostile environments, and require substantial movement or precise positioning, which can affect weld quality and safety, and are difficult to seal against contamination.
Innovation Solution
A force sensing transducer-based control system that detects mechanical force applied by the welder and converts it into a variable electrical signal to control welding machine parameters, allowing for wireless or wired transmission, and is designed to be compact and easy to use, with options for attachment to the welding torch or other body parts, simplifying control operations and environmental sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a foot pedal assembly is used to control welding machine output, then real-time control is achieved, but the control device becomes large and cumbersome requiring substantial space
Solution Approach 1:
The patent replaces the mechanical foot pedal assembly with a force sensing transducer that converts mechanical force directly into electrical signals. This substitution eliminates the need for mechanical linkages, potentiometers, and large structural components, achieving real-time control while dramatically reducing the control device volume to a compact handheld torch configuration
Solution Approach 2:
The welding torch is designed to serve multiple functions: it performs the welding operation and simultaneously serves as the control device through integrated force sensing transducers. The welder controls welding parameters by applying force to the torch handle or trigger, combining the welding tool and control interface into a single multi-functional device
2Ease of operation
If a foot pedal with cable connection is used, then control is achieved, but the cable becomes entangled with other cords and items in the work area
Solution Approach 1:
The patent extracts the control functionality from the separate foot pedal device and integrates it directly into the welding torch. This eliminates the need for a connecting cable between the control device and welding machine, as the force sensing transducer generates electrical signals directly within the torch, removing the source of cable entanglement problems
Solution Approach 2:
The force sensing transducer acts as an intermediary that converts mechanical force applied to the torch into electrical control signals. This intermediate conversion process eliminates the need for mechanical linkages and cables, allowing wireless or direct electrical signal transmission from the torch to the welding machine control system
3Ease of operation
If a hand operated control with sliding or rotating potentiometer is used, then control is achieved, but the control element requires accurate positioning which can affect weld quality
Solution Approach 1:
The patent replaces sliding or rotating potentiometers with force sensing transducers that measure applied force directly. This substitution eliminates the need for precise positioning of control elements, as the welder simply applies force to the torch handle or trigger in the natural direction of welding motion, removing the trade-off between control accuracy and weld quality
Solution Approach 2:
Instead of requiring the welder to position a control element accurately to achieve the desired control effect, the system inverts the approach by having the welder apply force in the natural direction of welding motion and having the force sensing transducer convert that force into the appropriate control signal. This reverses the traditional control paradigm and eliminates positioning requirements
4Ease of operation
If a foot pedal or hand control with moving parts is used, then control is achieved, but the control device is difficult to seal against contamination in hostile environments
Solution Approach 1:
The patent replaces mechanical linkages, sliding contacts, and rotating components with a force sensing transducer that has no moving parts. The transducer senses force through deformation of a sensing element and converts it directly into an electrical signal, eliminating mechanical interfaces that would require sealing against contamination in hostile welding environments
Solution Approach 2:
The force sensing transducer employs a flexible or deformable sensing element that can be encapsulated in a sealed housing. This flexible membrane or diaphragm allows force application from the external environment while maintaining a sealed barrier against contamination, enabling the control device to function reliably in hostile environments without complex sealing mechanisms
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 solution simplifies control operations by eliminating the need for substantial movement or precise positioning, enhances weld quality and safety, and reduces the risk of contamination, while being cost-effective and requiring less maintenance.
Implementation Method 1
a force sensing transducer for detecting a variable mechanical force applied to the sensor by the welder and converting the applied force into a corresponding variable electrical force signal
Data Source
AI summary
Apparatus for allowing a welder to control the output power of a welding machine, and thus its arc power by applying force to a surface of a force sensing transducer assembly. The force sensing transducer assembly generates a force signal based upon the force applied, for example by reducing the resistance within the force sensing transducer assembly. A control interface module then receives the force signal and controls the welding machine power output based upon the force signal. The welder may set the range of force to change the arc power by setting a minimum amount of force to actuate the welding machine and a maximum force that increases the output power of the welding machine (force below the minimum does not actuate the welding machine and force above the maximum does not increase the welding machine power above a certain level).