Optical Process Sensing for Nominal vs Off-Nominal Heat States
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Solution Overview
Problem
Manufacturing processes involving rapid heat addition and slower heat dissipation present challenges in monitoring and ensuring process consistency, as existing sensing methods struggle to accurately compare heat input and material response across different conditions, especially in high-temperature processes where optical radiation complicates data interpretation.
Innovation Solution
An optical sensing system utilizing spectrometry and feature extraction techniques, such as Fast Fourier Transform (FFT), to analyze heat source and material response features, enabling comparison with baseline conditions and determining nominal or off-nominal process states by measuring thermal and radiative emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical radiation from high-temperature processes is used for sensing, then process monitoring capability is improved, but data interpretation complexity increases
Solution Approach 1:
The patent segments the optical radiation spectrum into multiple wavelength bands, analyzing each band separately to extract specific process information. This segmentation approach simplifies the interpretation of complex spectral data by breaking it down into manageable components that correspond to different physical phenomena in the welding process
Solution Approach 2:
The patent introduces an intermediary processing layer that transforms raw optical radiation data into meaningful process parameters. This intermediary system includes algorithms and processing steps that convert complex spectral information into interpretable metrics about heat input, material response, and process quality
2Speed
If fast timescale heat input processes are monitored, then process control responsiveness is improved, but measurement accuracy deteriorates due to short interaction times
Solution Approach 1:
The patent employs periodic sampling of optical radiation at multiple wavelength bands during the heat input process. By capturing data at strategically timed intervals and combining information from different wavelengths, the system achieves accurate measurements despite the short interaction time characteristic of rapid heating processes
Solution Approach 2:
The patent transitions from temporal measurement alone to a multi-dimensional approach by incorporating spectral wavelength as an additional dimension. This allows the system to extract process information from multiple wavelength bands simultaneously, compensating for the limited time available for measurement in fast heat input processes
3Reliability
If separate comparison of heat input and material response is implemented, then process quality assurance capability is improved, but system complexity increases
Solution Approach 1:
The patent implements a universal sensing system that simultaneously monitors both heat input characteristics and material response using the same optical radiation measurement platform. By designing the system to perform multiple functions (measuring both process input and material reaction) through a single integrated approach, the patent reduces overall system complexity while maintaining comprehensive quality assurance capability
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
Enables effective classification of nominal vs. off-nominal conditions in manufacturing processes, optimizing energy coupling efficiency and ensuring process quality by deriving relevant features from thermal and spectral data, even in complex high-temperature environments.
Implementation Method 1
there are observable optical radiation from the process which can serve as the basis of a sensing mechanism
Data Source
AI summary
An optical manufacturing process sensing and status indication system is taught that is able to utilize optical emissions from a manufacturing process to infer the state of the process. In one case, it is able to use these optical emissions to distinguish thermal phenomena on two timescales and to perform feature extraction and classification so that nominal process conditions may be uniquely distinguished from off-nominal process conditions at a given instant in time or over a sequential series of instants in time occurring over the duration of the manufacturing process. In other case, it is able to utilize these optical emissions to derive corresponding spectra and identify features within those spectra so that nominal process conditions may be uniquely distinguished from off-nominal process conditions at a given instant in time or over a sequential series of instants in time occurring over the duration of the manufacturing process.