Inductive Welding Temperature Estimation Without External Sensors
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Solution Overview
Problem
Induction welding of lightweight materials, such as fiber composites, faces challenges in temperature measurement and control, particularly due to interference from thermocouples and electromagnetic fields, leading to inaccurate readings and potential overheating or underheating issues.
Innovation Solution
A system where an inductor acts both as a welding device and a sensor, generating an electromagnetic field to heat the workpieces while simultaneously measuring parameters to estimate temperature, allowing for controlled welding without external sensors, using techniques like neural networks or autoregressive models to determine temperature based on detected changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If thermocouples or other external temperature sensors are integrated to measure weld zone temperature, then temperature measurement capability is improved, but the thermal and mechanical performance of the material is degraded due to interference and electromagnetic field heating
Solution Approach 1:
The patent extracts the temperature measurement function from physical sensors and implements it through electromagnetic field-based indirect measurement. The inductor's electrical parameters (impedance, frequency, phase angle) are monitored to infer temperature without contacting the weld zone, thereby eliminating sensor interference with material performance.
Solution Approach 2:
The patent introduces electrical parameters of the inductor as an intermediary medium to measure temperature. Instead of directly measuring temperature with sensors, the system measures changes in the inductor's electrical characteristics which correlate with temperature, providing indirect but non-invasive measurement.
2Manufacturing precision
If external temperature sensors are used to monitor weld zone, then temperature control accuracy is improved, but device complexity and cost increase due to additional sensors and complex geometrical arrangements
Solution Approach 1:
The inductor serves dual functions: it both generates the electromagnetic field for heating and acts as the sensing element for temperature measurement. By monitoring the inductor's own electrical parameters, the system eliminates the need for separate sensing components, reducing overall system complexity while maintaining temperature control accuracy.
Solution Approach 2:
The inductor monitors its own operating conditions by measuring its electrical parameters (impedance, frequency, phase angle). This self-diagnostic capability allows the system to determine weld zone temperature without external sensors, simplifying the overall system architecture.
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 approach enables precise temperature control, reducing the risk of overheating or underheating, ensuring high-quality welds with improved mechanical properties and cost-effectiveness by eliminating the need for external sensors, thus enhancing the recyclability and lifetime of the workpieces.
Implementation Method 1
a processing means configured to generate an electromagnetic field by applying an alternating voltage to the inductor so as to inductively heat the at least one of the surfaces
Implementation Method 2
generate an electromagnetic field by applying an alternating voltage to the inductor so as to inductively heat
Implementation Method 3
The processing means is also configured to simultaneously measure at least one parameter of the at least one workpiece, at least based on the generated electromagnetic field
Data Source
AI summary
A system for controlled induction welding of at least one weld seam area (A) of at least two surfaces of at least one workpiece is provided. The system comprises an inductor configured to be arranged in conjunction with the at least one workpiece, a processing means configured to generate an electromagnetic field by applying an alternating voltage to the inductor so as to inductively heat at least one of the surfaces so that the weld seam area (A) is welded together, simultaneously measure at least one parameter (P) of the at least one workpiece at least based on the generated electromagnetic field, detect a change of the at least one parameter (P), and determine a temperature estimation of the at least one workpiece based on said detected change.