Torch Coolant Level Detection Using Reservoir Temperature Feedback

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Solution Overview

Problem

The level of coolant circulating between a torch and a reservoir can decrease due to leakage or blockages, leading to reduced cooling capacity and potential damage to the torch.

Innovation Solution

A control system monitors the temperature of coolant in the reservoir and compares it to a threshold temperature or rate of change to determine the coolant level, outputting a signal to suspend operation or prompt replenishment when the level is low.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If coolant is circulated through the torch to cool it, then the torch temperature is reduced and structural integrity is maintained, but the coolant level may decrease due to leakage or blockages reducing cooling capacity

Engineering Contradiction:

Improvetorch temperatureVSAvoidcooling capacity

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The system uses temperature sensors to continuously monitor coolant temperature at multiple locations (inlet and outlet of the torch) and feeds this information back to the control system. The control system compares actual temperatures with expected temperatures to detect coolant level issues and adjusts operation accordingly, maintaining reliable cooling capacity.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces direct mechanical level sensing with a thermal-based detection system. By monitoring temperature differences and heat transfer characteristics of the coolant, the system indirectly determines coolant level and flow conditions without requiring direct contact with the coolant or complex mechanical level sensors.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If the coolant level is monitored using traditional level sensors, then the coolant level can be directly detected, but the system complexity and cost increase

Engineering Contradiction:

Improvecoolant level detection accuracyVSAvoidsensing system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The system uses temperature as an intermediary parameter to infer coolant level. Instead of directly measuring coolant level with specialized sensors, the system measures coolant temperature and uses thermal models to determine level information, simplifying the sensing system while maintaining measurement capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the measurement parameter from direct level measurement to temperature measurement. By monitoring temperature changes in the coolant and correlating them with expected thermal behavior at different coolant levels, the system achieves level detection using standard temperature sensors rather than complex level sensing equipment.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If the torch operates continuously with insufficient coolant, then productivity is maintained, but the torch may overheat and suffer damage

Engineering Contradiction:

Improvewelding/cutting operation continuityVSAvoidtorch overheating and damage

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The control system performs preliminary detection of coolant sufficiency by continuously monitoring temperature parameters before critical overheating occurs. When temperature indicators suggest insufficient coolant level, the system takes preventive action by adjusting operation or alerting the operator, preventing damage before it happens while minimizing interruption to productivity.

Inventive Principle:

Principle #10Preliminary action

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

Maintains the structural integrity and efficiency of the torch by preventing excessive temperature increases due to insufficient coolant, thereby extending its lifespan and ensuring reliable operation.

Implementation Method 1

The control system is configured to determine a temperature of coolant in the reservoir

Methodology Applied

Scientific EffectTemperature measurement:

Implementation Method 2

a heat exchanger configured to reduce a temperature of coolant in the reservoir

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Data Source

PatentUS20250319542A1Coolant level sensing for torch system

Publication Date: 2025.10.16 ESAB GROUP INC

AI summary

A torch system includes a torch configured to perform a welding or cutting operation, a reservoir configured to store coolant, a conduit system configured to circulate coolant between the reservoir and the torch to cool the torch, and a control system. The control system is configured to determine a temperature of coolant in the reservoir, the temperature of coolant in the reservoir indicating a level of coolant circulating between the reservoir and the torch, compare the temperature of coolant in the reservoir to a threshold temperature, and output a signal in response to determining the temperature of coolant in the reservoir exceeds the threshold temperature.