Welding Torch Threshold Sensing for Planned Maintenance Prep

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Solution Overview

Problem

Conventional robotic welding systems experience unplanned downtime due to inadequate maintenance scheduling, leading to increased troubleshooting time and complexity, which can be minimized by predicting and preparing for torch maintenance ahead of time.

Innovation Solution

The implementation of sensors, such as cameras and thermal sensors, to monitor welding torch conditions and control circuitry that determines when maintenance is required based on threshold violations, allowing for proactive preparation and notification for maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional maintenance scheduling is used, then welding torch operational life continues, but unplanned downtime increases due to inadequate maintenance timing

Engineering Contradiction:

Improvewelding torch operational lifeVSAvoidunplanned downtime

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary maintenance actions by monitoring torch conditions in real-time and scheduling maintenance before actual failures occur. Sensors detect degradation trends and trigger maintenance protocols proactively, preventing unplanned downtime while extending operational life through timely interventions.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system implements continuous feedback loops where sensors monitor torch conditions (temperature, wear, performance metrics) and feed this data back to the control system. This feedback enables dynamic adjustment of maintenance scheduling based on actual torch health status, optimizing the balance between operational life and downtime prevention.

Inventive Principle:

Principle #23Feedback

2Reliability

If maintenance is performed more frequently, then reliability improves, but productivity decreases due to increased maintenance interruptions

Engineering Contradiction:

Improvewelding torch performanceVSAvoidwelding output

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system transitions from static, fixed-interval maintenance schedules to dynamic, condition-based maintenance scheduling. Maintenance frequency automatically adjusts based on real-time torch conditions, allowing extended operation when torch health is good and proactive maintenance when degradation is detected, thereby optimizing both reliability and productivity.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the maintenance parameter from fixed time intervals to condition-based triggers. By monitoring parameters such as temperature, wear rates, and performance metrics, the system determines maintenance timing based on actual torch state rather than predetermined schedules, reducing unnecessary maintenance interruptions while maintaining reliability.

Inventive Principle:

Principle #35Parameter changes

3Measurement precision

If sensors and monitoring systems are added, then maintenance prediction accuracy improves, but device complexity increases

Engineering Contradiction:

Improvetorch condition monitoring accuracyVSAvoidmaintenance system structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The system employs multi-functional sensors that monitor multiple torch parameters (temperature, wear, electrical characteristics) simultaneously. This universal monitoring approach improves measurement precision across various condition metrics while avoiding the complexity increase that would result from installing separate dedicated sensors for each parameter.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system combines sensor data acquisition, analysis, and maintenance scheduling functions into an integrated control system. By merging these previously separate functions into a unified platform, the system achieves high measurement precision through comprehensive monitoring while reducing overall device complexity through functional integration and centralized processing.

Inventive Principle:

Principle #5Merging (Combining)

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 approach reduces downtime by enabling predictive maintenance, simplifying the maintenance process, and improving the overall performance and effectiveness of welding torches by preparing for maintenance before failures occur.

Implementation Method 1

a camera or an optical sensor mounted on a helmet configured to monitor one or more visual indicators related to a temperature of the welding torch

Methodology Applied

Scientific EffectVisual indicator detection:

Implementation Method 2

The one or more sensors is a thermal sensor configured to monitor a temperature of the welding torch

Methodology Applied

Scientific EffectThermal detection:

Data Source

PatentUS20240326150A1Conditions-based torch maintenance systems

Publication Date: 2024.10.03 ILLINOIS TOOL WORKS INC

AI summary

A system for torch maintenance includes: at least one sensor configured to monitor one or more conditions of a welding torch; and control circuitry configured to: receive feedback corresponding to the one or more conditions from the at least one sensor; determine that the feedback received from the at least one sensor violates one or more thresholds; and command the system to prepare for torch maintenance when the feedback violates the one or more thresholds.