Oxygen Sensor Control Unit for Welding Process Data Analysis
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Solution Overview
Problem
Existing welding technologies lack precise measurement and analysis of oxygen concentration in the shielding atmosphere during shielded arc welding, leading to inadequate quality control and difficulty in optimizing the welding process, particularly for materials like titanium, tantalum, and zirconium, where low oxygen content is crucial for high-quality welds.
Innovation Solution
A device equipped with a control unit and sensor elements, such as optical or zirconium dioxide sensors, to measure and collect oxygen concentration data during welding, allowing for real-time monitoring and storage of data for analysis and process optimization, with the control unit capable of communicating with the welding apparatus and processing data for quality assurance and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If oxygen sensors are used to detect oxygen content, then oxygen concentration can be measured, but the measured values are not processed or correlated with welding progress, making detailed analysis difficult
Solution Approach 1:
The patent implements a control unit that continuously receives oxygen concentration data from sensors during welding and feeds this information back for real-time analysis. The system correlates oxygen levels with welding progress parameters (current, voltage, travel speed) to provide comprehensive process feedback, enabling detailed analysis and optimization of welding quality.
Solution Approach 2:
The control unit acts as an intermediary between the oxygen sensors and the welding apparatus. It collects, processes, and correlates data from multiple sources (oxygen concentration, welding parameters, progress information) to generate comprehensive process analysis, bridging the gap between measurement and actionable insights.
2Ease of operation
If calculation formulae based on time, amount of gas and volume are used, then oxygen content can be estimated, but only approximate reference values are obtained which are not sufficient for high-quality applications
Solution Approach 1:
The patent replaces manual calculation methods with automated optical oxygen sensors and electronic data processing. The system uses optical absorption measurements at specific wavelengths (760nm) to directly measure oxygen concentration, eliminating the need for approximate calculations based on gas flow parameters and providing precise real-time measurements.
Solution Approach 2:
The system changes the measurement parameter from indirect calculation (based on gas flow rate, time, volume) to direct optical measurement (based on light absorption at 760nm wavelength). This parameter change enables precise oxygen concentration measurement without relying on approximate formulas.
3Object-affected harmful factors
If shielding gas is used to displace oxygen, then oxidation can be prevented, but it is difficult to determine whether the region has been sufficiently flooded with shielding gas
Solution Approach 1:
The patent uses oxygen sensors to provide real-time feedback on the effectiveness of shielding gas coverage. By continuously monitoring oxygen concentration in the welding region and correlating it with welding progress, the system determines whether sufficient shielding gas has been applied and provides feedback for optimization.
Solution Approach 2:
The system replaces visual inspection methods with electronic oxygen sensing and data correlation. Instead of relying on visual cues or manual assessment of shielding gas coverage, the system uses automated optical sensors to measure oxygen levels and correlates this data with welding parameters to objectively determine shielding effectiveness.
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 detailed analysis of the welding process, improves weld seam quality, and allows for real-time adjustments to maintain optimal oxygen levels, enhancing the consistency and quality of welds by correlating oxygen concentration with welding progress and enabling data-driven optimization.
Implementation Method 1
The at least one sensor element is designed as an optical oxygen sensor... based on the principle of the light adsorption of oxygen atoms preferably at a wavelength of 760 nm
Implementation Method 2
They operate on the Nernst principle... If the zirconium dioxide layer is heated to over 350°C, it becomes an oxygen ion conductor... ultimately causing a voltage to drop across the two electrodes
Data Source
AI summary
The present invention relates to a device for measuring and collecting oxygen concentration data in welding processes, in particular in shielded arc welding. The device has at least one sensor element for sensing the oxygen concentration of a shielding atmosphere,and further a control unit, which is designed for storing oxygen concentration data during a welding process.