Optical Weld Torch Speed Sensing for Manual Travel Measurement
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Solution Overview
Problem
Existing welding systems face challenges in accurately measuring the travel speed of a welding torch during manual welding operations due to environmental and operator-related factors.
Innovation Solution
An optical-based travel speed sensing system is employed, which includes optical sensors configured to detect light emitted or reflected from the welding arc. This system determines the travel speed of the welding torch by processing signals from these sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual welding operations are used, then operator flexibility and adaptability are improved, but measurement of weld motion becomes more difficult
Solution Approach 1:
The patent introduces an optical sensor as an intermediary device that indirectly measures weld motion by detecting light reflected from the workpiece surface. This mediator allows measurement of manual welding torch movement without directly interfering with the operator's manual dexterity or the welding process itself.
Solution Approach 2:
The patent replaces direct mechanical measurement methods with an optical sensing system. Instead of using mechanical encoders or position sensors on the torch, the system uses optical sensors to detect surface features and calculate torch position and motion, thereby maintaining operator flexibility while enabling measurement.
2Measurement precision
If optical sensors are used to measure weld motion, then measurement capability is improved, but system complexity increases
Solution Approach 1:
The optical sensor system uses the workpiece surface itself as a reference by detecting reflected light from surface features. The system is self-calibrating in the sense that it uses the actual workpiece geometry visible to the sensor, eliminating the need for separate calibration fixtures or complex reference systems.
Solution Approach 2:
The system creates an optical copy or image of the workpiece surface features through the optical sensor. By tracking the position and movement of these visual features in the optical field, the system derives torch position and motion information without physical contact or complex mechanical linkages.
3Manufacturing precision
If travel speed monitoring is implemented, then welding parameter control is improved, but real-time measurement capability is reduced due to environmental factors
Solution Approach 1:
The patent converts the harmful effect of bright welding arc light into a useful signal by using optical sensors to detect reflected light from the workpiece surface. The same optical field that contains the welding arc also contains reflected light from surface features, which can be used for measurement. Filters and signal processing distinguish the useful reflected light from the harmful arc glare.
Solution Approach 2:
The patent uses reflected light from workpiece surface features as an intermediary carrier of motion information. Instead of directly measuring torch position, the system measures the movement of visual features on the workpiece surface, which serves as a reliable intermediary that is less affected by the harsh welding environment.
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 optical-based sensing system effectively measures the travel speed of the welding torch, enabling precise monitoring of weld parameters and improving the consistency of welding operations.
Implementation Method 1
an optical sensor configured to sense light incident on the optical sensor
Implementation Method 2
The optical sensor is configured to sense light incident on the optical sensor, and the travel speed sensing system is configured to determine a travel speed of the welding torch, a direction of the welding torch, or both, based on the sensed light
Data Source
AI summary
A travel speed sensing system includes an optical sensor configured to be coupled to a welding torch. The optical sensor is configured to sense light incident on the optical sensor, and the travel speed sensing system is configured to determine a travel speed of the welding torch, a direction of the welding torch, or both, based on the sensed light.