Detachable Welding Sensor Module for Real-Time Angle Feedback
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Solution Overview
Problem
Conventional welding technique monitoring systems face challenges in accurately assessing and providing feedback on welding technique quality, particularly for less experienced operators, as they struggle to determine good or bad technique effectively.
Innovation Solution
A tool-based welding technique monitoring system with a detachable sensor module that tracks the orientation of a welding tool using inertial measurement units, providing real-time feedback on parameters like work angle, travel angle, and travel speed, and allows for simple calibration across various joint types, including horizontal, vertical, and sloped joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional welding technique monitoring systems are used, then welding quality can be monitored, but the systems are expensive, complex, and difficult to operate
Solution Approach 1:
The system divides the monitoring function into a portable sensor module that can be detached from the welding tool. This segmentation allows the complex monitoring electronics to be separated from the tool itself, reducing the complexity burden on the operator while maintaining monitoring capabilities. The sensor module contains all necessary sensors and processing, making the main tool simpler.
Solution Approach 2:
A wireless communication intermediary transmits data between the sensor module and the monitoring system. This intermediary allows the sensor module to be detached and reused across different tools without complex wiring, reducing system complexity while maintaining measurement precision through reliable data transmission.
2Ease of operation
If conventional welding technique monitoring systems are used, then welding quality feedback is provided, but the systems are not portable and require complex installation
Solution Approach 1:
The sensor module is designed to be dynamically attachable and detachable from the welding tool, transitioning between portable and integrated states. This dynamic configuration allows the system to be easily transported and installed on different tools while maintaining measurement precision through consistent sensor positioning and calibration capabilities.
3Reliability
If fixed sensor modules are integrated into welding tools, then monitoring is stable, but the tools cannot be easily modified or upgraded
Solution Approach 1:
The monitoring system is segmented into a separate sensor module that attaches to the tool rather than being permanently integrated. This segmentation provides stable monitoring through dedicated sensor housing while allowing easy removal and adaptation to different tool types or configurations.
Solution Approach 2:
The sensor module is designed with universal attachment capabilities that allow it to function with multiple types of welding tools. This multi-functionality provides reliable monitoring across different tools while enabling easy adaptation and upgrade without tool-specific integration constraints.
4Manufacturing precision
If comprehensive welding technique monitoring is implemented, then welding quality improves, but the cost increases
Solution Approach 1:
The sensor module is designed as a cost-effective, potentially disposable component that provides comprehensive monitoring capabilities without requiring expensive permanent installation. This approach improves welding quality through accurate monitoring while keeping the system cost low by using economical sensor technologies and modular design.
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
The system offers an inexpensive, portable, and robust solution that enhances welding quality by providing accurate real-time feedback, supporting diverse joint orientations with easy calibration procedures, thus improving the overall welding process.
Implementation Method 1
tracks the orientation of a welding tool using inertial measurement units
Data Source
Figure 1
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Figure 2c
AI summary
Described herein are examples of tool based welding technique monitoring systems that provide an inexpensive, intuitive, and relatively robust way of tracking an orientation of a welding-type tool, and providing welding technique feedback based on the orientation. The system requires no sensors apart from a simple and/or relatively inexpensive sensor module that can be mounted to travel with the welding-type tool, which makes the system highly portable. Additionally, calibration of the system can be accomplished with fast, simple, intuitive calibration techniques.