Multi-Torch Brazing Control With Mass Flow Flame Regulation
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Solution Overview
Problem
Existing brazing systems with multiple adjustment valves face challenges in maintaining consistent gas flow rates and oxygen-to-fuel ratios, leading to quality issues and difficulty for operators in setting appropriate flame settings, especially due to variations in temperature and gas pressure.
Innovation Solution
A brazing system with a touch screen display and controller circuit board that supports single or multiple torch configurations, using mass flow controllers to monitor and adjust fuel and oxygen/air gas flow rates, and a wireless communication system for data collection and management, allowing for precise control and synchronization of flame settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual needle metering valves are used to control gas flow, then operators can adjust gas flow rates, but the gas flow rates and oxygen-to-fuel ratios become inconsistent due to temperature and pressure variations
Solution Approach 1:
The patent replaces manual needle metering valves (mechanical system) with mass flow controllers that use electronic sensors and control algorithms to automatically regulate gas flow rates, eliminating the inconsistency caused by manual adjustment while maintaining ease of operation through digital control interfaces
Solution Approach 2:
The system implements feedback control by continuously monitoring gas flow rates and oxygen-to-fuel ratios through sensors, then automatically adjusting the mass flow controllers to maintain consistent parameters despite temperature and pressure variations, resolving the precision issue while keeping the system easy to operate
2Ease of operation
If multiple adjustment valves are used in brazing systems, then gas flow can be controlled, but operator error increases and quality issues arise due to difficulty in setting appropriate flame settings
Solution Approach 1:
The system performs self-adjustment by automatically controlling gas flow rates and oxygen-to-fuel ratios through mass flow controllers based on pre-programmed parameters, eliminating the need for operators to manually set multiple valves and thereby reducing operator error while maintaining ease of operation
Solution Approach 2:
The patent changes the control parameters from manual valve positions to electronically controlled mass flow rates, allowing for more precise and reliable flame settings through digital parameter adjustment rather than mechanical valve positioning, which improves reliability while keeping the interface simple
3Device complexity
If a single controller is used for multiple torches, then system complexity is reduced, but independent control of each torch becomes difficult
Solution Approach 1:
The controller is segmented into multiple independent control channels, each capable of independently managing a torch's gas flow rates and parameters, while being integrated into a single controller unit that provides a unified interface, thus maintaining low device complexity while enabling independent torch control
Solution Approach 2:
The single controller is designed with multi-functionality to handle multiple torches simultaneously, with each torch having its own set of mass flow controllers and control parameters, allowing the system to maintain simplicity while providing versatile independent control for each torch
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 ensures consistent and reproducible flame settings across multiple torches, improving brazing quality and reducing operator error by automating the adjustment of gas flow rates and data management, enhancing efficiency and accuracy.
Implementation Method 1
The mass flow controllers are configured to independently monitor and adjust flow rates of a fuel gas for each of multiple fuel gas outputs of the system, and flow rates of an oxygen/air gas for each of multiple oxygen/air gas outputs of the system
Implementation Method 2
Brazing is one of the known methods of joining metal members together with a brazing filler, i.e., a metal or alloy having a lower melting point than the metals to be joined
Implementation Method 3
One of the gases will include a flammable fuel gas such as LP gas, natural gas, acetylene gas, methane, propane, butane, hydrogen and mixtures and combinations thereof, while the other gas will include a combustion-assisting gas such as oxygen or air
Data Source
AI summary
A brazing system includes a touch screen display and a controller circuit board having a processor and a memory. The controller circuit board is configured to be manually set by an operator to support a single torch configuration or a multiple torch configuration. The single torch configuration includes a first integrated software having first computer-executable instructions stored in the memory and configured to execute on the processor, and the multiple torch configuration includes a second integrated software having second computer-executable instructions stored in the memory and configured to execute on the processor. The multiple torch configuration supports the independent setting up of multiple brazing torches and the simultaneous use of the multiple brazing torches by multiple users during multiple independent brazing processes. The controller circuit board is operatively connected to the touch screen display and configured to allow user interaction with the controller circuit board via the touch screen display.