Welding Torch Nozzle Contact Detection for Continuous Welding
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Solution Overview
Problem
During welding processes, unplanned physical and electrical contacts between the welding torch and the workpiece can occur, leading to damage and reduced weld quality, as existing collision detection methods often require force thresholds and interrupt the welding process, causing delays and quality issues.
Innovation Solution
Applying an electrical voltage to an external element of the welding torch, such as a gas nozzle, via resistors connected to the welding current source and the workpiece, allowing for real-time detection of contacts through voltage and current measurements, enabling immediate countermeasures to prevent damage and maintain continuous welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If collision boxes are used to detect physical contact by force threshold, then damage to workpiece or welding torch is prevented, but welding process is interrupted causing delays and reduced productivity
Solution Approach 1:
The patent replaces the mechanical force-based collision detection system with an electrical detection system. By applying a detection voltage to the gas nozzle and monitoring for electrical contact (through current flow or voltage change), the system can detect contacts without the mechanical complexity and interruptive nature of force-based collision boxes, thereby maintaining welding continuity while preventing damage
Solution Approach 2:
The patent introduces an electrical intermediary (detection voltage and current monitoring) between the welding torch and workpiece contact detection. This intermediary electrical signal allows for early detection of contacts before they become physical collisions that would trigger force-based collision boxes, enabling continuous welding while maintaining protection
2Reliability
If force-based collision detection is used to identify contacts, then safety is ensured, but damage can already occur between first contact and threshold reaching
Solution Approach 1:
The patent applies a detection voltage to the gas nozzle before and during the welding process, enabling preliminary and continuous detection of electrical contacts. This preliminary detection capability identifies contacts at the moment they occur, rather than waiting for force thresholds to be reached, allowing immediate corrective action to maintain weld seam quality
Solution Approach 2:
The patent implements continuous feedback by monitoring electrical current or voltage changes during the welding process. This real-time feedback mechanism detects contacts as they happen and can trigger immediate responses, preventing the delay inherent in force-based systems and ensuring consistent weld quality
3Reliability
If welding process is interrupted to prevent damage, then workpiece and torch are protected, but weld seam continuity and quality are reduced
Solution Approach 1:
The detection voltage serves as an intermediary that enables continuous monitoring without interrupting the welding process. By detecting electrical contacts through current or voltage changes, the system can identify issues early and respond appropriately while maintaining weld continuity, unlike force-based systems that require process interruption
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 method allows for quick identification and mitigation of contacts during the welding process, reducing the need for force-based collision detection and ensuring continuous, high-quality welds by detecting physical and electrical contacts in real-time, thereby preventing damage to the workpiece or torch.
Implementation Method 1
an electrical voltage is applied, at least temporarily, during the welding process to an external element of the welding torch, in particular to an outer wall of a gas nozzle, and a possibly occurring electrical contact between the external element and a further element
Implementation Method 2
a welding current source is supplied in order to provide a welding voltage
Data Source
AI summary
In a method in which a welding process is carried out on a workpiece with a welding torch and to a welding device for carrying out the method, a welding current source is supplied in order to provide a welding voltage, and an electrical voltage is applied, at least temporarily, during the welding process to an external element of the welding torch, in particular to an outer wall of a gas nozzle, and a possibly occurring electrical contact between the external element and a further element, in particular the workpiece or a contact tube, is detected by the electrical voltage applied. The welding current source is electrically connected via at least one first resistor to the external element of the welding torch and the external element of the welding torch is connected to the electrical potential of the workpiece via at least one second resistor.