Oxy-Fuel Torch Flame Sensing for Sensorless Standoff Detection
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Solution Overview
Problem
Current automated gas cutting torch systems face inconsistencies in operation due to vulnerabilities in sensor technologies, particularly in kindling temperature detection, automatic ignition, and standoff control, which are sensitive to harsh environments and require additional costly electronics, diminishing reliability.
Innovation Solution
An oxy-fuel thermal processing system that utilizes electrical characteristics of the torch flame to detect parameters such as kindling temperature, standoff distance, and flame quality by applying a voltage or current between isolated surfaces, eliminating the need for physical sensors and probes, and using a microprocessor to adjust the cutting process accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical sensors are mounted within the torch directed down the cutting oxygen orifice for kindling temperature detection, then detection capability is improved, but the system becomes vulnerable to abrasion and particulate deposition
Solution Approach 1:
The patent replaces optical sensors with electrical field-based detection. A high-frequency AC voltage is applied between the torch and workpiece, and the resulting current through the flame is measured. This electrical field method eliminates mechanical/optical sensors that are vulnerable to abrasion and particulate deposition, providing reliable kindling temperature detection without physical contact with the harsh cutting environment.
2Extent of automation
If additional electronics and hardware are mounted on or inside the gas cutting torch for automated features, then automation capability is improved, but system cost increases and reliability diminishes
Solution Approach 1:
The patent implements self-service automation where the flame itself serves as the sensing medium. The flame's electrical conductivity properties are measured directly during cutting operations, eliminating the need for separate sensor systems. The cutting process provides its own feedback signal through the flame's response to the applied AC voltage, enabling automated control without additional vulnerable electronics in the torch.
Solution Approach 2:
The patent makes the cutting torch itself multi-functional by using it both for cutting and for sensing. The same torch that delivers the cutting flame also serves as the electrode for electrical field-based detection. This eliminates the need for separate sensor mounting hardware and reduces system complexity while maintaining automation capabilities.
3Ease of operation
If optical sensors are mounted on the exterior of the torch for standoff control, then standoff measurement capability is improved, but the sensors become susceptible to being obscured, scratched or damaged by debris
Solution Approach 1:
The patent replaces exterior-mounted optical sensors with electrical field-based standoff detection. A high-frequency AC voltage is applied, and changes in the electrical field characteristics as the torch approaches the workpiece are measured. This method provides standoff control without exposing any physical sensors to the harsh environment, as the electrical field penetrates through the flame and gases without being affected by debris.
4Volume of moving object
If the diameter of the torch's cutting oxygen bore is too small to accommodate an optical sensor, then torch portability is improved, but kindling temperature detection cannot be implemented
Solution Approach 1:
The patent replaces optical sensors with electrical field-based detection that requires no physical space within the torch bore. The high-frequency AC voltage is applied between the torch and workpiece, and the flame's electrical conductivity is measured externally. This eliminates the need to accommodate optical sensors within the cutting oxygen bore, maintaining small torch size while enabling kindling temperature detection.
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 provides reliable, economical, and robust automation of gas cutting torches by accurately determining kindling temperature, maintaining optimal standoff distance, and ensuring consistent ignition and flame quality, reducing hardware and maintenance costs while enhancing operational reliability.
Implementation Method 1
The flame between a torch and a work piece ionizes an otherwise non-conductive gas, thereby completing an electrical circuit
Data Source
AI summary
An automated oxy-fuel thermal processing system including an oxy-fuel torch, an automated machine tool operatively coupled to the torch for moving the torch relative to a work piece, and a circuit including a voltage source or a current electrically connected to the torch and configured to be electrically connected to the work piece. The automated oxy-fuel thermal processing system may further include a processor that is operatively connected to the torch, the automated machine tool, the circuit, and the voltage source or current source, wherein the processor is configured to control the operation of the torch, the automated machine tool and the voltage source or current source, and to monitor a current or voltage in the circuit in a predefined manner.