Welding Cable Sensor Connector With Inductive HF Isolation

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Solution Overview

Problem

Welding apparatuses face challenges in monitoring and tracking various parameters such as voltage and current during the welding process, especially when obtaining power from welding cables, as high frequency and high voltage signals can disrupt the voltage signals, impacting arc ignition and overall welding functionality.

Innovation Solution

A connector and sensor unit that derives power from welding cables using inductors as RF chokes to isolate high frequency signals, allowing for the monitoring and communication of welding parameters to a communications unit without disrupting the welding process, and includes current and voltage sensing circuitry to generate necessary power for internal circuitry and the communications unit.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If power is derived directly from welding cables without isolation, then the connector and sensor unit can be powered, but high frequency and high voltage signals disrupt voltage sensing and impact arc ignition

Engineering Contradiction:

Improvepower supply to connector and sensor unitVSAvoidarc ignition and welding process stability

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

An inductor is introduced as an intermediary component between the welding cable and the connector/sensor unit power input. The inductor acts as an RF choke that blocks high frequency welding signals from reaching the voltage sensing circuitry while still allowing DC power to pass through, thus isolating the sensitive electronics from the high frequency welding environment

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The high frequency welding signals are extracted or removed from the power path by the inductor before they can reach the voltage sensing circuitry. This separation allows the connector unit to derive power from the welding cable without being affected by the harmful high frequency components

Inventive Principle:

Principle #2Taking out (Extraction)

2Measurement precision

If voltage sensing circuitry is placed in the high frequency environment, then voltage monitoring is possible, but the high frequency signals disrupt the voltage sensing accuracy

Engineering Contradiction:

Improvevoltage sensing capabilityVSAvoidhigh frequency signal interference

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The inductor serves as a protective intermediary that filters out high frequency interference from reaching the voltage sensing circuitry, allowing accurate voltage measurement while protecting the sensing electronics from the harsh high frequency welding environment

Inventive Principle:

Principle #24Intermediary (Mediator)

3Loss of information

If the connector and sensor unit monitors welding parameters, then welding process tracking is improved, but the unit requires additional power that may interfere with welding cables

Engineering Contradiction:

Improvewelding parameter monitoring capabilityVSAvoidpower consumption from welding cables

Core Design Contradiction:

Loss of informationVSLoss of energy

Solution Approach 1:

The inductor enables the connector unit to extract and use power from the welding cable without allowing the high frequency welding signals to pass through to the electronics, thus enabling parameter monitoring while preventing energy loss and interference

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The potentially harmful high frequency signals and power consumption requirements are converted into a beneficial arrangement where the inductor allows the unit to be powered from the welding cable while blocking the harmful high frequency components, turning a potential problem into a solution

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

Enables effective monitoring and communication of welding parameters without interfering with the welding process, ensuring reliable arc ignition and data transmission for improved welding operations and analysis.

Implementation Method 1

supply power circuitry configured to generate a predetermined voltage for at least the current sensor circuitry, wherein the supply power circuitry receives power from at least one of the first welding cable and the second welding cable and via at least one inductor

Methodology Applied

Scientific EffectElectromagnetic Induction: Electromagnetic Induction

Data Source

PatentUS11204394B2External connector and sensor unit for welding equipment

Publication Date: 2021.12.21 ESAB AB

AI summary

A connector and sensor unit for a welding apparatus, including a first port configured to be connected to a first welding cable of the welding apparatus, a second port configured to be connected to a second welding cable of the welding apparatus, current sensor circuitry configured to sense a current being supplied by the first welding cable and the second welding cable, and to output a corresponding current sense signal, voltage sensing circuitry configured to sense a voltage between the first welding cable and the second welding cable, and to output a corresponding voltage sense signal, and supply power circuitry configured to generate a predetermined voltage for at least the current sensor circuitry, wherein the supply power circuitry receives power from the first welding cable and the second welding cable via at least one inductor.