Optical Weld Torch Speed Sensing for Real-Time Heat Input Control
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Solution Overview
Problem
Manual welding operations face challenges in measuring weld travel speed due to environmental and operator-related factors, making it difficult to monitor and control heat input and torch position accurately.
Innovation Solution
An optical-based travel speed sensing system is integrated with the welding torch, using optical sensors to detect light from the welding arc or reflected light, allowing for the determination of torch travel speed, direction, and position, which can be used to evaluate heat input and adjust welding parameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical sensors are integrated with the welding torch to measure travel speed, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The optical sensor is integrated directly into the welding torch assembly, combining the sensing function with the welding operation. This merging allows travel speed measurement without requiring separate external measurement equipment, thereby improving measurement precision while managing device complexity through functional integration.
Solution Approach 2:
The patent uses optical fields as an intermediary to measure torch position and speed. By introducing light as a mediator between the torch and the measurement system, the invention achieves precise travel speed measurement without direct mechanical contact or complex sensor arrangements, resolving the contradiction between measurement precision and device complexity.
2Measurement precision
If multiple optical sensors are disposed about the weld area to improve measurement accuracy, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The measurement function is segmented across multiple optical sensors positioned at different locations around the weld area. Each sensor captures specific optical information, and the combined data from these segmented sensing points enables comprehensive torch position and speed measurement, improving precision while distributing system complexity across multiple simpler sensor units.
3Manufacturing precision
If real-time monitoring of welding parameters is implemented, then manufacturing precision is improved, but loss of time increases due to data processing
Solution Approach 1:
The system implements real-time feedback by continuously monitoring optical signals from the welding arc and immediately using this information to determine torch travel speed and position. This feedback loop enables real-time welding parameter monitoring and adjustment, improving manufacturing precision while minimizing time loss through direct, continuous measurement rather than periodic sampling.
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 effectively monitors and adjusts welding parameters in real-time, improving the consistency and quality of welds by accurately measuring torch travel speed and position, applicable to both manual and automated welding processes.
Implementation Method 1
The optical sensors are configured to sense light emitted from a welding arc produced by the welding torch
Implementation Method 2
using optical sensors to detect light from the welding arc or reflected 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.