Weld Heat Sensing Feedback for Real-Time Parameter Control
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Solution Overview
Problem
Current welding processes, particularly electric resistance welding, face challenges in optimizing multiple parameters simultaneously, including spatial and thermal relationships, which affects the quality and efficiency of the weld process.
Innovation Solution
A heat energy sensing and processing system that captures time-sequenced data arrays from the weld region, processes this data to produce heat energy data sets, and adjusts welding parameters in real-time using a digital infrared camera or other heat sensors, along with protective enclosures and controlled sight paths to minimize noise and contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple welding parameters are optimized simultaneously, then weld quality and efficiency improve, but process complexity increases
Solution Approach 1:
The patent implements real-time thermal sensing during the welding process to monitor heat distribution and temperature fields. This feedback mechanism allows the system to automatically adjust welding parameters (current, speed, pressure) based on actual thermal conditions, enabling simultaneous optimization of multiple parameters while maintaining manageable process complexity through automated control
Solution Approach 2:
The patent replaces manual parameter adjustment and visual inspection with automated thermal sensing systems and computer-controlled parameter adjustment. The thermal camera and processing system substitute for human operators in monitoring and controlling welding parameters, reducing process complexity while improving weld quality consistency
2Measurement precision
If real-time heat energy sensing is implemented, then process control precision improves, but system complexity and cost increase
Solution Approach 1:
The thermal sensing system serves multiple functions: monitoring heat distribution, measuring temperature fields, detecting welding defects, and providing feedback for parameter adjustment. This multi-functionality justifies the added system complexity by delivering comprehensive process control and quality assurance in a single integrated system
Solution Approach 2:
The patent introduces a thermal camera as an intermediary device that non-contactly measures heat energy and temperature fields. This intermediary enables precise thermal measurement without interfering with the welding process, achieving high measurement precision while adding minimal intrusion to the existing welding system
3Stability of the object's composition
If thermal sensing data is processed and used for automatic parameter adjustment, then weld consistency improves, but processing time and computational requirements increase
Solution Approach 1:
The system performs preliminary thermal sensing and analysis during the welding process itself, before the weld completes. This allows real-time detection of deviations and immediate parameter adjustments, ensuring weld consistency without requiring post-processing or rework, thus minimizing time loss
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 system enhances the precision and quality of the welding process by providing real-time heat energy data for process control, allowing for automatic adjustments of parameters such as vee length, angle, and pressure, leading to improved weld seam consistency and product quality.
Implementation Method 1
A heat energy sensing device captures a series of time-sequenced heat energy data arrays or data stream sets of a weld process region
Implementation Method 2
The supplied current heats up the strip edges via induction or directly applied electrodes
Implementation Method 3
induction coil 121 to induce current in the metal around a 'V' (vee) shaped region formed by forcing edges of the strip together
Implementation Method 4
electrical contacts 34a and 34b. The supplied current heats up the strip edges
Implementation Method 5
electric resistance welding (ERW), which can be used to weld the seam of tubular articles
Data Source
Figure 1(a)
Figure 1(b)~3
Figure 2
AI summary
A series of time sequenced heat energy data arrays or data stream sets of a weld process region are processed by a weld data array or data stream processing system to produce a heat energy data set output that is related to weld process region features or weld process region heat energy data. The heat energy data set output can be displayed to a system user and modified by system user input to the weld data array or data stream processing system; alternatively, or in combination, the system user output and input, the heat energy data set output, or data produced from the heat energy data set output by the weld data array or data stream processing system, can be transmitted to a weld process controller to adjust parameters in the weld process responsive to the output of the weld data array or data stream processing system.