Retractable Cord Torch Tracking for Low-Cost Weld Monitoring

Solution Overview

Problem

Conventional welding torch tracking systems are complex and expensive, making them unsuitable for widespread adoption in quality welding applications, where proper torch manipulation is crucial for high-quality welds.

Innovation Solution

A simple and cost-effective torch tracking system utilizing a retractable cord reel with sensors to measure travel speed, distance, and direction, integrated with a welding helmet for real-time feedback and monitoring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional welding torch tracking systems are used, then tracking functionality is achieved, but system complexity and cost increase

Engineering Contradiction:

Improvetorch tracking accuracyVSAvoidsystem complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces complex electronic tracking systems with a simple mechanical reel-based system. The retractable cord reel mechanically tracks torch movement through cord extension and retraction, eliminating the need for complex sensors, processors, and power supplies while maintaining effective tracking functionality for welding training and monitoring.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs inexpensive, simple components such as a basic retractable cord reel, sensor, and control circuitry that can be easily replaced or upgraded. This approach reduces overall system cost and complexity while providing sufficient tracking capability for welding technique monitoring and training applications.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Measurement precision

If conventional welding torch tracking systems are used, then tracking functionality is achieved, but system cost increases

Engineering Contradiction:

Improvetorch tracking accuracyVSAvoidsystem cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The patent replaces expensive electronic tracking systems with a simple mechanical reel-based system. The retractable cord reel mechanically tracks torch movement through cord extension and retraction, eliminating the need for complex sensors, processors, and power supplies while maintaining effective tracking functionality for welding training and monitoring.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs inexpensive, simple components such as a basic retractable cord reel, sensor, and control circuitry that can be easily replaced or upgraded. This approach reduces overall system cost and complexity while providing sufficient tracking capability for welding technique monitoring and training applications.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Device complexity

If simple tracking systems are used, then cost and complexity are reduced, but measurement precision may decrease

Engineering Contradiction:

Improvesystem simplicityVSAvoidtracking accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent incorporates a sensor that detects cord extension and retraction, providing feedback signals to a control system. This feedback mechanism enables the system to accurately determine torch travel speed, distance, and direction despite using simple mechanical components, maintaining measurement precision while keeping the system simple and cost-effective.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces complex electronic tracking systems with a simple mechanical reel-based system. The retractable cord reel mechanically tracks torch movement through cord extension and retraction, eliminating the need for complex sensors, processors, and power supplies while maintaining effective tracking functionality for welding training and monitoring.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Provides accurate and affordable tracking of welding torch movement, enhancing welding technique quality by offering real-time feedback and reducing the complexity and cost associated with traditional systems.

Implementation Method 1

a reel with a retractable (and/or extendable) cord. The reel or cord can be attached to some portion of the welding torch, such that movement of the torch away from the reel causes the reel to extend more cord, and movement towards the reel allows a spring loaded spool of the reel to automatically retract the cord.

Methodology Applied

Scientific EffectSpring mechanism: Spring

Data Source

PatentUS20220126404A1Tracking welding torches using retractable cords

Publication Date: 2022.04.28 ILLINOIS TOOL WORKS INC

AI summary

Described herein are examples of torch tracking systems that monitor travel directions, speeds, and/or distances of welding torches using retractable cords. In some examples, the torch tracking systems use a sensor to measure a speed at which a reel extends and/or retracts a cord, and/or measure a length of the cord that is extended and/or retracted. The reel or cord can be attached to some portion of the welding torch, such that movement of the torch away from the reel causes the reel to extend more cord, and movement towards the reel allows a spring loaded spool of the reel to automatically retract the cord. While reel based torch tracking systems may provide coarser tracking than the more complex and/or expensive torch tracking solutions, their simplicity and low cost may make them an attractive alternative.