Double-Layer Tube Heating With Non-Contact Weld Temperature Sensing
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Solution Overview
Problem
Current heating systems for producing double-layer copper-coated steel tubes lack precise control over the joining temperature and melting temperature of the copper layer during the welding process, leading to suboptimal welding conditions.
Innovation Solution
A heating system with a temperature sensor positioned to monitor the welding point between the steel and copper layers, allowing for controlled temperature adjustment within the casing, featuring a control unit and display for real-time temperature feedback and manual adjustment, ensuring the copper layer is heated to its melting point for seamless tube production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature sensor is positioned inside the casing to directly measure the welding temperature, then the measurement precision would be high, but the sensor would be damaged by the high temperature and harsh welding environment
Solution Approach 1:
A transparent window is introduced as an intermediary element between the sensor and the high-temperature welding zone. The window allows thermal radiation to pass through to the sensor while physically isolating the sensor from the harsh environment, thus maintaining both measurement accuracy and sensor reliability
Solution Approach 2:
The patent replaces direct physical contact measurement with non-contact optical measurement. The sensor detects temperature through thermal radiation passing through the transparent window, eliminating the need for the sensor to be physically present in the high-temperature zone
2Reliability
If the sensor is positioned far from the welding point to avoid high temperature, then the sensor reliability is maintained, but the temperature measurement precision decreases
Solution Approach 1:
The transparent window serves as a mediator that enables the sensor to be positioned outside the high-temperature zone while maintaining measurement precision. It transmits thermal radiation from the welding point to the sensor without requiring the sensor to be in close proximity to the heat source
3Measurement precision
If the casing is made fully transparent to allow sensor observation, then the measurement precision is improved, but the protective function of the casing against high temperature is reduced
Solution Approach 1:
Instead of making the entire casing transparent, only a localized transparent window is introduced at the specific position where temperature monitoring is needed. The rest of the casing maintains its opaque, heat-protective properties, thus balancing measurement requirements with thermal protection
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 precise control of the welding temperature, ensuring consistent and high-quality joining of steel and copper layers, resulting in reliable and efficient production of seamless double-layer steel tubes with improved mechanical properties.
Implementation Method 1
a sensor configured in an outer portion of the casing such that the sensor is able to determine temperature value inside the casing
Implementation Method 2
a heating system for manufacture of copper coated double-layer steel tubes having a casing in which the roll-wrapped tube forms are heated to a predefined temperature value
Implementation Method 3
Joining temperature in a double-layer steel tube is the melting temperature of the copper layer
Data Source
AI summary
A heating system for use in the manufacture of copper coated double-layer steel tubes having a casing in which the roll-wrapped tube is heated to a predefined temperature value. The heating system comprises a sensor configured in an outer portion of the casing such that the sensor is able to determine a temperature value within the casing.