Portable Optical Welding Speed Sensor
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Solution Overview
Problem
Existing welding arc position and speed detection systems are not portable, require additional hardware, and struggle with sensor uniformity and manufacturing variances, limiting their effectiveness and usability in live welding operations.
Innovation Solution
A portable optical sensor system that detects the welding arc's light without additional markers, using sensor normalization, position calculation algorithms, and spark-rejection techniques to provide accurate and reliable position and speed data, allowing for flexible welding operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If welding sensors are mounted to the welding gun, then the system can track the welding gun position, but it requires additional hardware attached to the welding gun which restricts welder freedom of movement and natural feel
Solution Approach 1:
The patent extracts the detection function from the welding gun itself and places sensors in the vicinity of the work area instead. The system uses sensors positioned near the welding zone to detect arc light and calculate position, eliminating the need for attachments on the welding gun while maintaining detection capability.
Solution Approach 2:
The patent introduces an intermediary computational approach where the system detects arc position by analyzing light emitted from the arc itself rather than tracking the gun. This intermediary method of detecting arc light as a proxy for gun position enables freedom of movement while maintaining measurement precision.
2Measurement precision
If welding sensors are mounted to the ceiling or pedestal, then the system can detect welding arc position, but it is not portable and requires materials to be brought to a specific work area
Solution Approach 1:
The patent implements a dynamic sensor configuration where sensors are positioned in the vicinity of the work area rather than fixed to ceiling or pedestal. This dynamic arrangement allows the system to be relocated to different work areas while maintaining detection precision, enabling portability without sacrificing measurement capability.
3Measurement precision
If multiple sensors are used to track welding arc position, then measurement accuracy can be improved, but sensor uniformity issues and manufacturing variances cause varying results for the same incident light
Solution Approach 1:
The patent applies preliminary calibration to each sensor before deployment. The system characterizes each sensor's response to incident light and stores calibration data that is used to normalize readings during operation. This preliminary action compensates for manufacturing variances and ensures consistent, reliable measurements across all sensors.
Solution Approach 2:
The patent changes the parameters of sensor readings by applying calibration factors and normalization based on each sensor's characteristics. The system adjusts sensor output parameters to account for manufacturing variations, transforming raw inconsistent data into standardized reliable measurements that can be directly compared across different sensors.
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 precise and portable detection of welding arc position and speed, simplifying setup and use, while compensating for sensor variations and manufacturing errors, providing timely and accurate feedback for welders.
Implementation Method 1
This invention is a system for using optical sensors to detect and calculate the position and speed of a welding arc during a live welding operation. This system senses the light emitted by the welding arc itself
Data Source
AI summary
A system (10) and method for determining welding speed employing a series of optical sensors (28) positioned along a weld joint (12) that collects light source location data during an actual weld.