Torch Component Imaging for Automatic Consumable Identification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for identifying interchangeable torch components for welding and cutting torches are inefficient, often relying on visual identification, barcodes, RFID, pressure decay, or surface reflectivity, which can be unreliable, expensive, or impractical, especially for inexperienced users.
Innovation Solution
The implementation of a torch assembly with imaging devices positioned within the internal cavity to optically acquire images of markings on interchangeable torch components, allowing for automatic recognition and identification based on these markings, which can be passive, mechanical, and inexpensive to produce.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If visual identification or bar code scanning is used to identify torch components, then the identification process can be performed with simple equipment, but the process is unreliable and difficult for inexperienced users
Solution Approach 1:
The patent replaces manual visual identification and bar code scanning with an automated optical imaging system. The torch assembly includes an imaging device (camera) that automatically captures images of markings on components, and a processor that analyzes these images to identify component type, authenticity, and compatibility. This substitution eliminates the need for users to manually scan bar codes or visually inspect components, thereby improving reliability while maintaining ease of use.
Solution Approach 2:
The torch assembly performs self-identification of its own components through the integrated imaging device and processor. When a component is installed, the system automatically detects it by imaging its markings and processes the image to identify the component type, eliminating the need for external identification tools or user intervention. This self-service approach improves both reliability and ease of operation.
2Extent of automation
If RFID tags are used for component identification, then automatic identification is achieved, but the cost increases and older parts become incompatible
Solution Approach 1:
Instead of using RFID tags or other electronic identification methods, the patent uses optical copying of visual markings on components. The imaging device captures an optical image of the component's markings (such as text, symbols, or patterns), and the processor analyzes this optical copy to identify the component. This approach achieves automatic identification without requiring expensive RFID tags, maintaining compatibility with older parts that already have visual markings.
Solution Approach 2:
The patent substitutes electronic RFID identification systems with an optical-mechanical imaging and image processing system. By using a camera to capture images and a processor to analyze marking patterns, the system achieves automated identification without the cost and compatibility issues of RFID technology.
3Extent of automation
If pressure decay measurement is used for component identification, then identification can be performed, but the process is time-consuming and inaccurate for worn consumables
Solution Approach 1:
The patent places the imaging device and processing logic in advance within the torch assembly, ready to immediately identify components upon installation. The system continuously monitors for component installation and automatically triggers image capture and analysis, eliminating the time delay associated with manual pressure decay measurements. The identification occurs instantly when the component is in place, not after a time-consuming measurement process.
Solution Approach 2:
The patent replaces the time-consuming pressure decay measurement process with immediate optical imaging and image processing. Instead of waiting for pressure changes to occur and measure them, the system instantly captures an image of the component's markings and processes it for identification, dramatically reducing the time required for component identification.
4Ease of operation
If manual adjustment of power supply settings is required, then users can control operational parameters, but the process is tedious and may lead to unsafe operations
Solution Approach 1:
The torch assembly automatically identifies the installed component and self-configures the appropriate operational settings. The processor determines the component type from the imaged markings and automatically adjusts power supply parameters, gas flow rates, and other operational settings to match the identified component's specifications. This eliminates the need for users to manually consult manuals or adjust settings, reducing time and preventing unsafe operations while maintaining optimal performance.
Solution Approach 2:
The system uses feedback from the component identification process to automatically adjust operational parameters. Once the component is identified through image analysis, the system feeds this information back to the power supply and control systems, which then automatically configure the appropriate settings. This closed-loop feedback mechanism ensures that settings are always matched to the installed component without requiring user intervention.
5Device complexity
If visual or bar code identification is used, then no additional hardware is needed on components, but counterfeit or unsuitable components are difficult to identify
Solution Approach 1:
The patent analyzes specific local features of component markings to identify authenticity and suitability. The image processing system examines particular characteristics such as the precise positioning of text, specific symbol patterns, manufacturing tolerances of printed features, and other localized marking qualities that are difficult to replicate in counterfeits. By focusing on these specific local qualities rather than general appearance, the system can reliably distinguish genuine components from counterfeits without adding hardware to the components themselves.
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 solution enables reliable and consistent identification of torch components, automatically adjusts operational parameters such as power and gas settings, and prevents unsafe or suboptimal operations, enhancing safety, efficiency, and reducing costs associated with maintenance and part replacement.
Implementation Method 1
one or more imaging devices are disposed within the internal cavity and are positioned to optically acquire an image or image data representative of the one or more markings included on the one or more interchangeable torch components
Data Source
AI summary
Automatically recognizing interchangeable torch components, such as consumables, for welding and cutting torches includes adding one or more passive markings to a surface of an interchangeable torch component. Then, the interchangeable component can be recognized by a torch assembly including a torch body and one or more imaging devices or by a system including the torch assembly and a power supply. The torch body has an operative end configured to removably receive the interchangeable torch component. The one or more imaging devices are positioned to optically acquire an image of or image data representative of the one or more passive markings included on the interchangeable torch components so that a processor can determine if the one or more interchangeable components are genuine.