Partitioned Sensor Cooling Case for Welding Radiant Heat
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Solution Overview
Problem
Existing welding sensors face temperature increases due to radiant heat and sensor-generated heat during gas-shielded arc welding, with existing cooling mechanisms not effectively addressing radiant heat, which affects sensor performance and longevity.
Innovation Solution
A sensor protecting case with centralized cooling portions and strategically positioned gas inflow and outflow ports to create independent cooling spaces for both the sensor main body and input portion, utilizing a gas flow rate of 100 to 200 L/min to efficiently cool the sensor, particularly the lens, which is exposed to radiant heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a cooling mechanism is added to the sensor, then the sensor temperature is reduced, but the device complexity increases
Solution Approach 1:
The sensor housing is divided into multiple independent cooling chambers (first cooling chamber, second cooling chamber, third cooling chamber) separated by partitions. Each chamber has dedicated gas inflow and outflow ports, allowing independent cooling zones that can be optimized for different thermal loads without requiring a single complex cooling system.
Solution Approach 2:
Different regions of the sensor housing are provided with different cooling configurations. The first cooling chamber cools the sensor main body, while the second and third cooling chambers specifically cool the sensor input portion that is exposed to radiant heat. This localized cooling approach addresses specific thermal problems in different areas without over-cooling the entire sensor.
2Measurement precision
If the sensor is positioned close to the welding heat source, then the weld condition observation is improved, but the sensor is more affected by radiant heat
Solution Approach 1:
Cooling gas acts as an intermediary substance that absorbs radiant heat before it reaches the sensor. The gas flows through the cooling chambers and creates a thermal barrier between the welding heat source and the sensor, allowing the sensor to maintain accurate observations while being protected from excessive heat exposure.
Solution Approach 2:
The radiant heat that would normally harm the sensor is converted into a beneficial cooling effect. The cooling gas absorbs the radiant energy in the cooling chambers, transforming the harmful thermal radiation into useful cooling that maintains sensor temperature within operational limits while allowing close positioning for better observation.
3Temperature
If gas flow rate is increased, then the cooling effect is enhanced, but the energy consumption increases
Solution Approach 1:
The cooling system divides the gas flow into multiple separate streams through different cooling chambers. Each chamber receives a portion of the total gas flow, allowing the system to achieve effective cooling across the entire sensor without requiring excessively high flow rates in a single channel. This segmented approach distributes the energy requirement across multiple lower-flow paths.
Solution Approach 2:
Different cooling chambers are provided with different gas flow rates based on the specific thermal requirements of each sensor region. The sensor input portion chambers (second and third cooling chambers) that are most exposed to radiant heat receive higher flow rates, while the sensor main body chamber receives lower flow, optimizing the overall cooling efficiency and reducing total energy consumption.
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 configuration enables effective local cooling of the sensor input portion and main body, enhancing sensor performance and longevity by managing heat effectively, even in high-heat environments near welding sources.
Implementation Method 1
causing gas to flow into the centralized cooling portion and causing the gas to flow out of the centralized cooling portion
Data Source
AI summary
A sensor protecting case is provided with a case main body for housing a sensor main body and a sensor input portion, and a centralized cooling portion that is partitioned off by a partition so as to include at least part of the sensor input portion, and constitutes an independent space within the case main body. The case main body has a first gas inflow port for causing gas to flow into the case main body, and a first gas outflow port for causing the gas to flow out of the case main body. The partition has a second gas inflow port that is connected to the first gas inflow port to cause the gas to flow into the centralized cooling portion, and a second gas outflow port for causing the gas to flow out of the centralized cooling part into the case main body.