Gas Nozzle Voltage Sensing for Real-Time Welding Contact Detection
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Solution Overview
Problem
Unplanned physical and electrical contacts during welding processes can disrupt the quality of the weld seam and cause damage to the workpiece or welding torch, as existing methods rely on force thresholds that may not detect contacts in real time, leading to interruptions and reduced production efficiency.
Innovation Solution
Applying an electrical voltage to an external element of the welding torch, such as a gas nozzle, via resistors and a voltage divider, allows for real-time detection of contacts through changes in voltage and current, enabling immediate countermeasures to prevent damage and maintain continuous welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If collision boxes are used to detect contact by force threshold, then contact detection is achieved, but welding process interruptions occur and production efficiency decreases
Solution Approach 1:
The patent replaces the mechanical force-based collision box system with an electrical detection system. A voltage is applied to the external element (gas nozzle), and any physical contact is detected through changes in electrical current or voltage, eliminating the need for mechanical force threshold detection and subsequent process interruptions.
Solution Approach 2:
The system continuously monitors electrical parameters (voltage or current) during the welding process. When contact is detected through electrical parameter changes, immediate feedback allows for real-time correction without interrupting the welding process, maintaining both reliability and productivity.
2Object-affected harmful factors
If welding process is interrupted to prevent damage, then workpiece or torch damage is avoided, but weld seam quality deteriorates due to discontinuous welding
Solution Approach 1:
The electrical detection system provides continuous real-time monitoring during welding. When contact is detected through voltage or current changes, the system can trigger immediate corrective actions (such as adjusting torch position or pausing only momentarily) without fully interrupting the welding process, thus preventing damage while maintaining weld seam continuity and quality.
Solution Approach 2:
The system detects contact at the earliest stage through electrical parameter changes before significant damage can occur. This preliminary detection allows for preventive corrective actions to be taken immediately, avoiding both damage and the need for welding interruptions.
3Reliability
If early contact detection is implemented, then damage prevention is improved, but device complexity increases due to additional sensing systems
Solution Approach 1:
The external element (gas nozzle) serves dual functions: its original protective function and as an electrical sensing element for contact detection. By applying voltage to this existing component, the system achieves contact detection without adding separate sensing hardware, thus improving reliability while minimizing increased device complexity.
Solution Approach 2:
The patent combines the contact detection function with the existing external element structure. The electrical detection capability is integrated into the gas nozzle or outer wall, merging multiple functions into a single component rather than adding separate detection systems.
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 enables quick detection and prevention of unwanted contacts, reducing the need for force-based interruptions and ensuring consistent welding quality by allowing for real-time corrections during the process, thereby minimizing damage and maintaining production efficiency.
Implementation Method 1
a welding current source (18) for providing a welding voltage
Implementation Method 2
an electrical voltage is applied at least temporarily to an external element of the welding torch... and any electrical contact that may occur between the external element and a further element is detected using the applied electrical voltage
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
The invention relates to a method in which a welding process is performed on a workpiece (3) using a welding torch, and to a welding device (1) for carrying out the method, a welding device (1) being provided for carrying out the method, a welding current source (18) being provided in order to provide a welding voltage (USQ), and an electrical voltage (UD) being applied at least temporarily during the welding process to an external element (17) of the welding torch (5), in particular to an outer wall (9') of a gas nozzle (9) and any electrical contact (13, 14) occurring between the external element (17) and a further element (24 \ 24") being detected by means of the electrical voltage (UD) applied. In accordance with the invention it is provided that the welding current source (18) is electrically connected via at least one first resistor (19) to the external element (17) of the welding torch (5) and the external element (17) of the welding torch (5) is connected to the electrical potential of the workpiece (3) via at least one second resistor (21).