Programmable IR Temperature Sensing for Moving Welding Workpieces
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Solution Overview
Problem
Induction power sources used in welding applications, such as the ProHeat 35, face challenges in accurately measuring temperature on moving workpieces due to the limitations of traditional thermocouples and wide-range IR temperature sensors, which are sensitive to emissivity changes and often do not cover the required temperature range for heating devices like the ProHeat 35.
Innovation Solution
An adjustable temperature scale system that allows users to select a temperature sensor with desired operational characteristics, correlating the output signal range of the sensor to the specific temperature range needed, using a controller and program logic to generate accurate measured temperature values and control or monitor temperature effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a thermocouple is used to measure temperature on a moving workpiece, then the temperature can be measured at a specific point, but the measurement is inaccurate because the workpiece or sensor moves during heating
Solution Approach 1:
The patent replaces the mechanical contact-based thermocouple system with an optical/infrared-based temperature sensing system. The infrared sensor measures temperature remotely through thermal radiation detection, eliminating the need for physical contact with moving workpieces. This substitution resolves the contradiction by maintaining measurement precision while ensuring reliability on moving parts, as the optical system is not affected by mechanical movement or contact issues.
2Adaptability or versatility
If a wide-range IR temperature sensor is used to measure temperature on moving parts, then the sensor can cover a broad temperature range, but the measurement precision deteriorates due to sensitivity to emissivity changes
Solution Approach 1:
The patent applies local quality by configuring the infrared sensor to measure temperature within a specific, optimized temperature range rather than attempting to cover all possible temperatures. By focusing on a localized temperature range relevant to the welding application, the sensor achieves higher measurement precision and reduced emissivity sensitivity. This resolves the contradiction by sacrificing some adaptability to gain measurement precision in the critical operating range.
Solution Approach 2:
The patent changes the operational parameters of the infrared sensor by adjusting its sensitivity and measurement range settings. The controller is configured to interpret sensor outputs specifically calibrated for the welding temperature range, optimizing the sensor's performance characteristics. This parameter adjustment resolves the contradiction by tailoring the sensor's adaptability to match the specific application requirements, thereby improving precision within that range.
3Measurement precision
If an IR temperature sensor with limited temperature range is used, then the sensor is less sensitive to emissivity changes, but it cannot cover the required temperature range of the heating device
Solution Approach 1:
The patent achieves universality by using a single infrared sensor configuration that can handle multiple temperature ranges through programmable controller settings. The system can be adjusted via software to accommodate different welding applications and temperature requirements without changing the physical sensor hardware. This resolves the contradiction by making the limited-range sensor effectively multi-functional through parameter programming, thereby achieving both precision and adaptability.
4Measurement precision
If a single temperature sensor is used for a specific application, then the sensor can be optimized for that application, but it limits the versatility of the heating device for different applications
Solution Approach 1:
The patent applies dynamics by making the temperature sensor configuration changeable through software programming rather than being fixed. The controller can be reconfigured via parameter settings to accommodate different temperature ranges and sensor types. This dynamic configurability resolves the contradiction by allowing the system to be optimized for specific applications when needed while maintaining the capability to adapt to other applications, thereby achieving both precision and versatility.
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 temperature measurement and control across a required temperature range, even with moving parts, by using an IR temperature sensor with programmable sensitivity, reducing errors and expanding the application range of the ProHeat 35 and similar induction power sources.
Implementation Method 1
use another type of a temperature sensor, such an infrared (IR) temperature sensor
Data Source
AI summary
A device providing a temperature control and/or monitoring and a method for use of the device are disclosed. In the disclosed method and device, a controller receives a minimum temperature value and a maximum temperature value of a temperature range to be measured. The controller correlates a known output signal range of a temperature sensor to the temperature range to be measured. Further, the controller receives an output signal from the temperature sensor, and generates a measured temperature value based on the output signal of the temperature sensor.