Orbital Welding Head Oxygen Measurement via Optical Coupling
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Solution Overview
Problem
Existing orbital welding devices face issues with oxygen sensor damage due to heat during the welding process when placed within the housing, and arranging the sensor outside with a suction device is laborious and causes measurement delays.
Innovation Solution
An orbital welding device design where the optical oxygen sensor is positioned outside the shielding gas chamber, optically coupled via optical fibers or waveguides to the welding head or housing, allowing for protected and delay-free oxygen concentration measurement without the need for a suction device, enabling flexible placement and improved measurement reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the oxygen sensor is arranged within the housing forming the shielding gas chamber, then the measurement of oxygen concentration is direct and immediate, but the sensor is damaged by the heat of the welding process
Solution Approach 1:
The oxygen sensor is extracted from the shielding gas chamber housing and positioned externally. The sensor measures oxygen concentration through an optical coupling (optical window or fiber optic cable) that transmits light into the chamber without requiring the sensor to be physically present in the hot environment. This resolves the contradiction by separating the measurement function from the harsh thermal environment.
2Reliability
If the oxygen sensor is arranged outside the housing, then the sensor is protected from heat damage, but a suction device is required which makes the setup laborious and causes measurement delay
Solution Approach 1:
The mechanical suction device is replaced by an optical measurement system. Instead of physically extracting gas samples through suction, the system uses optical coupling to allow light to pass into the chamber where oxygen concentration is measured optically. This eliminates the complex mechanical suction apparatus and enables immediate measurement without delay.
3Reliability
If a suction device is used to connect the external oxygen sensor to the chamber, then the sensor remains protected, but the measurement process becomes delayed and more complex
Solution Approach 1:
An optical coupling (optical window or fiber optic cable) serves as an intermediary between the external oxygen sensor and the internal chamber environment. This intermediary allows optical signals to pass through while maintaining physical separation, enabling real-time measurement without the time delays associated with mechanical suction systems.
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 design protects the oxygen sensor from heat damage, provides immediate and accurate oxygen concentration measurements, and allows for more efficient welding processes by enabling the start of welding once the oxygen concentration falls below a predetermined threshold, reducing unnecessary waiting time.
Implementation Method 1
the oxygen sensor, preferably a light-sensitive area, e.g. of a photodiode, of the oxygen sensor, is optically coupled to the measuring region by means of an optical coupling
Implementation Method 2
the oxygen sensor, preferably a light-sensitive area, e.g. of a photodiode
Data Source
AI summary
An orbital welding device (1), having a welding current source (10) in a welding current source housing (11) and an orbital welding head (20), which is separate from the welding current source housing (11) and is connected to the welding current source (10) by a cable (2), the orbital welding head (20) having a pipe mount (21) and a welding electrode holder (22) for holding a welding electrode (23). An electric motor (31) is designed to drive the welding electrode holder (22) and thus turn it with respect to the pipe mount (21). The orbital welding head (20) has a chamber (50) for shielding gas. An optical oxygen sensor (40) is designed to measure an oxygen concentration in a measuring region (51) in the chamber (50). The oxygen sensor (40) is arranged outside the chamber (50) and is optically coupled to the measuring region (51) by an optical coupling.