Multi-Wavelength Temperature Detection for Resistive Welding
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Solution Overview
Problem
Current temperature measurement methods in tube and pipe mills are unreliable due to the absorption of infrared radiation by water and the changing ambient environment, making it difficult to accurately monitor weld temperatures and maintain product quality.
Innovation Solution
A system using a visible light camera that detects multiple distinct wavelengths, including red, blue, and green light, to measure the temperature of the weld by analyzing the ratios and patterns of these wavelengths, which are less affected by water vapor and smoke, allowing for repeatable and accurate temperature measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If infrared radiation is used for temperature measurement, then temperature detection capability is improved, but measurement reliability deteriorates due to water vapor absorption
Solution Approach 1:
The patent changes the detection parameter from infrared wavelength to visible light wavelengths (red, green, blue). This parameter change allows the system to avoid water vapor absorption while maintaining temperature detection capability through analysis of emitted light intensity ratios at different visible wavelengths.
Solution Approach 2:
The patent introduces visible light as an intermediary medium for temperature measurement. Instead of directly measuring infrared radiation which is absorbed by water vapor, the system uses visible light wavelengths that can penetrate the welding environment, analyzing the emitted light at multiple wavelengths to infer temperature.
2Device complexity
If single wavelength detection is used, then device complexity is reduced, but measurement precision deteriorates due to environmental variations
Solution Approach 1:
The patent segments the detection process into multiple wavelength channels (red, green, blue). By dividing the detection into distinct wavelength segments, the system can analyze the ratio of emitted light intensities at each wavelength to determine temperature, making the measurement independent of absolute intensity variations caused by environmental factors.
Solution Approach 2:
The patent adds the wavelength dimension to the detection process. Instead of measuring only the intensity at a single wavelength, the system measures intensity across multiple wavelength dimensions (red, green, blue), creating a multi-dimensional measurement space that enables temperature determination while compensating for environmental variations.
3Ease of manufacture
If operator visual inspection is used, then equipment cost is reduced, but measurement reliability and product quality deteriorate
Solution Approach 1:
The patent replaces the mechanical/visual inspection system with an optical detection system. Instead of relying on operator visual assessment, the system uses cameras or detectors to capture emitted light at multiple wavelengths and automatically calculate temperature, providing objective and reliable measurements.
Solution Approach 2:
The system enables the welding process to self-monitor its own temperature conditions. The welding environment itself (the hot metal) emits light that the detection system captures, allowing the process to provide its own measurement data without requiring external active heating or complex probe insertion.
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 reliable and repeatable temperature measurements in the welding environment, improving product quality and efficiency by accounting for variations in the ambient conditions and providing real-time alerts for deviations from optimal weld temperatures.
Implementation Method 1
the variation in emitted light intensity at different wavelengths across a range of temperatures
Implementation Method 2
absorption, scattering and refraction
Implementation Method 3
absorption, scattering and refraction
Data Source
AI summary
A temperature sensing system for a resistive welding process for a tube performs repeatable temperature measurement using a camera to detect multiple distinct visible light wavelengths even as the ambient environment in the view path changes. Sensed colors in a field of view in the vicinity of a weld are output to a computing element that calculates a corresponding temperature and alerts an operator when the sensed color exceeds a preset color range.