Weld Sensor Pod Cooling and Windowing Against Splatter
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Solution Overview
Problem
Manufacturing cells face challenges in protecting sensors from heat and hazardous materials generated during robotic operations, such as weld splatter, which can damage equipment and obstruct the sensors' line of sight.
Innovation Solution
The implementation of a sensor pod with a coolant circulation module and a consumable window made of transparent material, which can be easily replaced, along with a spray nozzle to clean foreign materials, shields the sensors from heat and debris, ensuring continuous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are positioned close to the weld head for real-time monitoring, then measurement precision is improved, but the sensors are exposed to heat and weld splatter which damages the sensors
Solution Approach 1:
The sensor system is divided into separate modular sensor pods that can be independently positioned and protected. Each sensor pod is a self-contained unit housing specific sensors, allowing the sensing function to be separated from the weld head while maintaining close proximity for accurate measurement.
Solution Approach 2:
A transparent window acts as an intermediary between the sensor and the weld zone. This window allows optical signals to pass through while protecting the sensor from heat and weld splatter. The window serves as a barrier that mediates between the need for close sensor positioning and the need for sensor protection.
2Reliability
If a protective enclosure is added around the sensor to shield from heat and debris, then reliability is improved, but the device complexity increases
Solution Approach 1:
Multiple protective and functional components are merged into a single integrated sensor pod assembly. The pod housing, transparent window, coolant channels, and mounting features are combined into one compact unit, reducing the number of separate components and simplifying installation while maintaining comprehensive protection.
Solution Approach 2:
A coolant circulation system uses fluid flow to remove heat from the sensor pod. Coolant channels are integrated into the pod housing, allowing continuous circulation of cooling fluid to dissipate heat generated during welding operations, providing active thermal management without complex mechanical shielding.
3Reliability
If a consumable window is added to protect the sensor, then the sensor reliability is improved, but the maintenance requirements increase due to window replacement
Solution Approach 1:
The transparent window is designed as a consumable, replaceable component that can be easily swapped when degraded. By making the window a disposable element rather than attempting to make it permanently durable, the system maintains high reliability while simplifying maintenance - the window is replaced rather than repaired when it becomes obscured or damaged.
Solution Approach 2:
The sensor pod system transitions from a static protective structure to a dynamic maintenance system. The consumable window is designed for quick replacement, and the pod itself can be rapidly exchanged between welding operations. This dynamic approach allows the system to adapt to wear and degradation without requiring complex repair 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
This solution effectively protects sensors from heat and debris, maintaining their functionality and reducing maintenance needs by allowing for quick replacement of consumable windows, thus ensuring reliable operation during robotic welding processes.
Implementation Method 1
a coolant circulation module configured to circulate a coolant through the pod housing
Implementation Method 2
a consumable window comprising a transparent material that is insertable into the receptacle such that a longitudinal axis of the sensor intersects the consumable window
Implementation Method 3
the sensor pod comprises a spray nozzle coupled to the front end of the pod housing, the spray nozzle configured to direct a flow of fluid towards the consumable window
Data Source
AI summary
A manufacturing cell for welding a workpiece includes a robotic arm extending between a base and a terminal end, a weld head coupled to the terminal end of the robotic arm such that the weld head is permitted to travel relative to the base of the robotic arm, wherein the weld head is configured to weld the workpiece, a sensor pod coupled to the weld head and including an outer pod housing defining an internal chamber extending between a front end and a rear end of the pod housing, and wherein the front end of the pod housing defines a receptacle, a sensor positioned in the internal chamber of the pod housing, the sensor configured to provide sensor feedback associated with the workpiece, and a consumable window including a transparent material is insertable into the receptacle such that a longitudinal axis of the sensor intersects the consumable window when the consumable window is inserted into the receptacle, and a controller coupled to the sensor pod and configured to operate at least one of the robotic arm and the weld head based on the sensor feedback provided by the sensor of the sensor pod.