Welding Torch Component Identification Using Passive Optical Markings
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Solution Overview
Problem
Existing welding and cutting torches require manual identification and adjustment of components, which can be difficult and unsafe, especially for inexperienced users, and often lead to inefficient operations due to incorrect settings or use of counterfeit components.
Innovation Solution
A system that automatically identifies interchangeable torch components using optical recognition techniques and adjusts operational parameters, such as power and gas settings, based on markings on the components, preventing unsafe or suboptimal operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual identification methods (visual inspection or bar code scanning) are used to identify torch components, then the system complexity remains low, but the reliability of component identification deteriorates due to difficulty in visual identification and inability to detect counterfeit components
Solution Approach 1:
The patent replaces manual visual inspection and bar code scanning mechanisms with an automated optical imaging and recognition system. The torch body includes an imaging device that captures images of component markings, and a processor that automatically recognizes and identifies the component type, eliminating the need for manual identification while improving reliability through automated optical recognition.
Solution Approach 2:
The system enables self-identification of torch components through automated optical recognition. The imaging device and processor work autonomously to identify components based on their markings, eliminating the need for operator intervention in the identification process and reducing reliance on manual methods that are prone to error.
2Reliability
If RFID tags are used for component identification, then the reliability of identification improves, but the manufacturing cost and device complexity increase significantly
Solution Approach 1:
The patent uses inexpensive passive optical markings (such as printed codes or visual identifiers) on disposable consumable components instead of expensive RFID tags. These markings can be applied during normal manufacturing processes and read by the optical imaging system, providing a cost-effective alternative that maintains identification reliability without requiring electronic components in each consumable part.
Solution Approach 2:
The patent substitutes electronic RFID identification systems with an optical recognition system that reads visual markings on components. This replacement eliminates the need for expensive electronic tags while achieving reliable component identification through image capture and automated optical recognition processing.
3Device complexity
If pressure decay measurement techniques are used for component identification, then the device complexity remains low, but the measurement precision and reliability deteriorate due to inaccuracies with worn consumables and slow identification speed
Solution Approach 1:
The patent replaces physical measurement techniques (pressure decay) with optical recognition methods. The imaging device captures visual information from component markings, and the processor automatically identifies components based on recognized patterns, providing faster and more accurate identification that is not affected by component wear or installation timing.
4Device complexity
If visual identification methods are used by operators, then the device complexity remains low, but the ease of operation deteriorates for inexperienced users and the productivity decreases due to time-consuming manual identification
Solution Approach 1:
The system performs self-identification of components without requiring operator knowledge or intervention. The automated optical recognition system independently identifies component types and communicates this information to the operator, eliminating the need for users to manually inspect or interpret component markings and simplifying operation for all skill levels.
Solution Approach 2:
The patent replaces manual visual inspection operations with automated optical imaging and recognition. The system automatically captures images of component markings, processes them through recognition algorithms, and provides identification results, eliminating the time-consuming manual identification process and improving ease of operation.
5Device complexity
If manual adjustment of power supply settings is required, then the device complexity remains low, but the productivity decreases and the reliability deteriorates due to potential incorrect settings and safety risks
Solution Approach 1:
The system implements automatic feedback control where the identified component information is used to automatically adjust power supply settings. The processor communicates component identification results to the power supply, which then configures appropriate operational parameters without requiring manual intervention, ensuring correct settings and improving productivity through automated parameter optimization.
Solution Approach 2:
The power supply system performs self-adjustment based on component identification. Once the component is automatically identified, the power supply automatically configures its output parameters to match the requirements of the identified component, eliminating the need for manual setting adjustment and reducing the risk of incorrect configurations.
6Ease of operation
If component identification is performed after installation, then the ease of operation improves, but the loss of time increases due to delayed identification and parameter adjustment
Solution Approach 1:
The system performs component identification immediately upon installation by capturing images of component markings as soon as the component is in place. The automated optical recognition system processes the images and identifies the component type without delay, enabling immediate parameter adjustment and eliminating time losses associated with delayed identification procedures.
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
Ensures accurate and reliable identification of components, prevents unsafe operations, and optimizes performance by seamlessly transitioning between different cutting or welding operations, reducing costs and extending equipment life.
Implementation Method 1
an imaging device that optically acquires an image of or image data representative of one or more markings included on one or more interchangeable torch components
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
Automatically identifying 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, automatic identification can be effectuated by a torch assembly (20) including a torch body (100) and one or more imaging devices (160) or a system including the torch assembly (20) and a power supply (40). The torch body (100) has an operative end (102) configured to removably receive one or more interchangeable torch components (200) including one or more passive markings (210). The one or more imaging devices (160) are positioned to optically acquire an image of or image data representative of the one or more passive markings (210) included on the one or more interchangeable torch components (200) so that the one or more interchangeable torch components can be automatically identified based on the one or more passive markings. Consequently, various components can be reliably and consistently identified.